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ONSHORE MAINT POTENTIAL PROG – NA2 ZONE

PROCEDURE FOR CONCRETE AND GROUTING WORK QTIF -716

CONTRACT NO: 6600042363 / BI-11-19000-9561

ISSUE FOR
0 06.05.2019 IFA
APPROVAL

REV DATE STATUS ISSUE PURPOSE PREPARED BY CHECKED BY APPROVED BY

CONTRACT No.: 6600042363 DOCUMENT No.: CPP-NA2-PM-PLN-0024

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DOCUMENT REVISION HISTORY SHEET

REV STATUS TRANSMITTAL NO. DATE ISSUED UPDATE / AMENDMENT DETAILS

0 IFA T-CPP-ARAMCO-NA2-00001 06.05.2019 ALL

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INDEX

1. Purpose
2. Scope
3. References
4. Definitions
5. Procedure
6. Documentation

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a) Purpose:

The purpose of this procedure is to provide a systematic method of performing Concrete

and grouting works. To ensure that all required inspection and tests have been
performed during construction and the work complies with all project specification
and drawing requirements.

b) Scope:

This procedure applies to all Concrete and Grouting works to be carried out by CPP and
its sub-contractors.
c) Reference:
The following documents are referenced.

SAES-Q-001 Criteria for Design and Construction of Concrete structures

SAES-Q-005 Concrete Foundations
SAES-Q-010 Cement based non-shrink grout for Structural and Equipment
Grouting
SAES-H-003 Protective coating for industrial concrete structures
09 SAMSS - 097 097 Ready mixed Portland cement concrete
09 SAMSS - 106 106 Epoxy Coating of steel reinforcing bars.
ACI 318 Building Code Requirements for Structural Concrete
ACI 304.2R Placing Concrete by Pumping Methods
ACI-301-05, ACI-304R, ACI-305R, ACI-308, ACI-308R, ACI-347, ACI-117,
ASTMA775, ASTM-C39
SAUDI ARAMCO TYPICAL INSPECTION PLAN
SATIP-Q-001-04 Structural Pre-cast Concrete at Fabrication Yard
SATIP-Q-001-02 Cast in place Portland Cement Concrete.
SATIP-Q-010-01 Cement Based Non-Shrink Grouting.
SATIP-H-003·0 1 Coating Application on Concrete Surfaces.
d) Definitions:

Concrete mix design: A document that details the requirements of concrete produced by the

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supplier.

e) Procedure:
• Concrete Works
• This procedure specification shall serve as guidelines for
implementation to meet the quality attributes in concrete construction
works. Civil Works Inspector shalt be responsible to the Project QC
Supervisor for all civil works. All concrete work shall meet the
requirement of Saudi Aramco Engineering Standard. SAES-Q-001,
SAES-0-005 & concrete shall conform to Saudi Aramco Specs. 09-
SAMSS-097 and supplied by Saudi Aramco approved source.
• Concrete mix design including recent test report for raw material; will
be submitted to Saudi Aramco for review and approval prior to
concrete placement.
• Cementite’s grout, testing and curing shall conform to SAES-Q-010,
Class I and mixed and placed as per manufacturers Instruction. All
concrete shall be placed on top of plastic sheets.
• The proportion of Ingredients shall be selected in accordance with
provisions of ACI 211.1, using a minimum cement content of 370 Kg.
Per cubic meter. The maximum allowable water cement ratio shall be
0.40 by weight for all concrete. Concrete shall possess a minimum
compressive strength of 4000 psi at 28 days, unless otherwise
specified. The test of fresh concrete shall include slump, unit weight,
air content and fresh concrete temperature. One complete set of test
shall be made for each set of cylinder.
• Concrete test cylinder shall be tested 1 at 3 days, 1at 7 days, 2 at 28
days as per 09-SAMSS-097.
• When concrete pumps are used, the slump shall be determined at the
discharge point of the concrete placement hoses as per 09-AMSS-097,
Para 7.2 and SAES Q-001, Sec.12

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• Concrete shall be delivered to the job site at a temperature not

exceeding 32 degree C. (90 Degrees F.) said temperature shall be
maintained for a period of time at least 15 minutes, after delivery.
Concrete not meeting the of time at least requirement of
og.sAMSS.097 shall be rejected.
• Concrete received at job site shall be tested by an independent testing
laboratory. Test results will be provided to SAUDI ARAMCO Rep as
soon as possible.

• Pre-pouring Requirements:
6.5.1 Formworks: -
 Material: -
Forms shall be made out of lumber or other suitable material that
can be hold concrete on place, attain required contour and
does no discoloration to the formed concrete surface.

 Workmanship: -
• Forms staff be built with mortar tight and of sufficient
rigidity to prevent distortion due to the pressure of
concrete and other loads incident to the construction
operation.
• Forms shall be constructed and maintained so as to
prevent wrapping and the opening of the joints due to the
shrinking of the lumber.
• Forms shall be so designed that the finished concrete
will conform to the proper dimension and contour
required in the plan.
• The forms shall withstand vibration works during
placing of concrete.
• The number and spacing of the form struts and braces

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shall be such that the forms will be braced rigidly and

uniformly. Joints between form sections shall be free
from play or movement
• Forms which are unsatisfactory in any respect shall not
be reused.

• Metal ties anchorage within the forms shall be

constructed as to permit their removal ta a depth at least
40 mm from the face without injury to the concrete.
• All wires, upon removal of the forms shall be cut-back at
least 10 mm from the face of the concrete with chisels or
snips.
• All fittings for metal ties shall be of such design that the
cavities produced upon their removal are the smallest
possible.
• Cavities shall be filled with cement mortar and the
surface left sound, smooth, even and Uniform in color.
All forms shall be cleaned and treated with oil before
any reinforcement steel is fitted. (Ref. SAES-Q-001).
• Materials which are adhering to or discolor the concrete
shall not be used.
• Struts, stays and braces serving temporarily to hold the
form in correct shape and alignment, pending the placing
of concrete at their location, shall be removed when the
concrete placing has reached an elevation rendering their
service unnecessary. These temporary members shall be
entirely removed from the forms and 'not buried in the
concrete.
• Plasticized vapor barrier shall be placed under all

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concrete structure resting on or below grade as per

SAES-0-001 section 11.

6.5.2 Steel Reinforcement-

All Concrete reinforcement shall conform to Saudi Aramco Engineering
Standards SAES-0-001, Appendix A and 09-SAMSS-106

 Material: -
• Epoxy coated rebar shall conform to 09-SAMSS-106.
The reinforcing bars to be epoxy coated shall be
deformed. The type and quality of the steel rods and bars
used shall conform to strength requirement and
minimum elongation as per ASTM A-615 or equivalent.
• The maximum amount of coating damage shall not
exceed 2% of the total surface area of each 0.3 m of the
bar. All visible damages to the epoxy coaling due to
shipping, handling, bending, cutting or placing shall be
repaired with patching material confirming to 09-
SAMSS-106. When epoxy coated rebar’s are cut the
ends of the bar shall be repair coaled.
• In the bend portion of the fabricated rebar, repairs
required if only hairline cracking Is present and there is
no discernible Joss of bond of the coating to the rebar.
When disbandment of the coating exists, the disbanded
bar shall be rejected

 Rebar Bending:
Rebar shall be bending on mandrels conforming to the size
Material Requirements of SAES·0-001 Appendix A. The mandrel
around which the rebar is bending shall be fabricated from nylon
to Tenor, which will not damage the epoxy coating. The minimum

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bend diameter shall be as follows:

Re-bar Diameter (mm) Benet diameter (mm)

6 48

8 64

10 80
12 96
14 112
16 128
20 160
22 178
25 200
28 224
32 256
36 288
40 400
45 450
50 500

5.2.2.3 Workmanship:
Workmanship shall comply with requirements of scope of Work.

• Rebar shall be placed in position as shown on the

drawings and firmly to prevent displacement before or
during the process of tamping and running the concrete
in place. Bar shall be laid at all interception except
where spacing is 300 mm. In each direction, in which
case alternate intersection shall be tied.

• All anchor bolts to be embedded shall be accurately

positioned and firmly secured against no movement
when using concrete by using wooden template.

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• Anchor bolts shall be coated with APCS-1C.

5.3 Pouring Specification:
• Concrete shall be placed so as to avoid segregation of the materials
and the displacement of their reinforcement. The use of long trough,
chutes and pipes from conveying from mixer to the forms shall not be
permitted unless authorized by Aramco. A standby vibrator and
generator shall be on site at the time of concrete placement as per
SAES-Q-001, Sec. 8.9 and ACl-309-R 5.5.
• Open trough or chutes shall be metal lined and with rounded cross
section to avoid the accumulation of concrete in comers.

• The Chutes shall be equipped with baffles or be in short lengths that

reverse the direction of movement.
• The slop shall be steep enough to permit follow without repairing a
slump greater than specified or required for placement
• All chutes, trough and pipes shall be kept clean and free from coating
of hardened concrete by thoroughly flushing with water after each
run. Water for flushing shall be discharged clear of the structure.
• When placing operations would involve dropping the concrete more
than 1.00 meters, it shall be deposited through sheet metal or other
approved pipes. (Ref SAES-Q-001).

• As far as practicable, the pipes shall be kept full of concrete during

piecing and their lower ends shall keep buried in the newly placed
concrete.

• Care shall be taken to avoid formation of cold joints. Concrete shall

be poured continuously without delay between layers. Excessive time
lapse of concrete will harden the outer surface of the poured concrete.
This hard surface will result in a cold joint between this layer and the
next layer. In case if excessive time lapse a bonding agent shall be

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applied to the previously poured surface, prior to pouring next layer

of concrete.
• The concrete shall be mixed properly with added chemical
admixtures/ plasticizer if necessary to safeguard against Insufficient
workability during placement
• After initial setting of concrete, the forms shall not be jarred no strain
shall be placed an end or reinforcing bars.

5.4 Consolidation: -
• Concrete, during and immediately after disposing shall be thoroughly
compacted.
• The compaction shall be done by mechanical Vibrations subject to the
following conditions in accordance with ACl-309.
• The vibration shall be internal unless special authorization of other
methods is given by Saudi Aramco or provided herein.
• Vibrator shall be a type and design approved by SAUDI ARAMCO
and capable of transmitting vibrations to the concrete at frequencies
of not less than 4500 impulses per minute.
• The intensity of vibrator shall be such as to visibly affect the mass of
concrete of 25 mm slump over a radius of at least 500mm

• The number of vibrators shall be sufficient to properly compact each

batch after it rs placed in the forms.
• The vibrations shall be of sufficient duration, generally 5 to 15
seconds, and intensity to thoroughly compact the concrete but shall be
discontinued at any point to the extent
• Applications of vibrations shall be at point uniformly spaced and not
further apart than the radius over which the vibration is visibly
effective.
• Vibration shall not be applied directly through the reinforcement lo

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section or layers of concrete which have hardened to the degree that

concrete to be plastic under vibration.
• Vibrators shall be manipulated so as to thoroughly work the concrete around
the reinforcement and embedded fixtures and into the comers and angles of
the forms.
• Vibrators shall not be used to transport concrete (Ref. SAES-Q-001.
7.5)

• Vibrators shall be supplemented by such spacing as necessary to

ensure smooth surface and dense concrete along form surface and in
comers and location impossible to reach with vibrators. (Per ACI 301-
18 chapter 8, Para. 8.3.4)
• Each layer shall be placed and compacted before the proceeding batch
has taken initial set to prevent injury lo the green concrete and avoid
surface of separation between the batches.
• The use of Implements such as compressor which is likely to disturb
or disarrange reinforcement or forms shall not be permitted.
• Concrete shall be placed in horizontal layers of not more than 450
mm. except when less than a complete layer is placed in one
operation and it shall be terminated in a vertical bulkhead. When the
placing of concrete is temporarily discontinued, the concrete after
becoming firm enough to retain its form shall be cleared of laitance
and other objectionable materials to a sufficient depth to expose
sound concrete. The top surface of concrete adjacent to the forms
shall be smoothed with trowel to avoid visible points as far as
possible upon exposed surface.
• Immediate following on approved discontinuance of placing concrete,
all accumulation of mortar splashed upon the reinforcement bars and
the surface of forms shall be removed. Dried mortar, chips and dust
shall not be puddle into inset concrete. If the accumulation Is not

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removed 'to the concrete becoming set, care shall be exercised not to
break the concrete
Steel bond at the end near the surface of the concrete while cleaning the
rebar.

5.5 Curing: -
• Concrete surface exposed to condition causing premature· drying or
wash by rain shall be protected by covering as soon as possible with
canvas, sand or other satisfactory material and kept moist, or if the
surfaces are not covered, they shall be kept moist by flushing,
sprinkling or pounding.
• Curing shall commence immediately after concrete takes initial set
and shall be continuous allowing no opportunity to drying out. Curing
shall be in accordance with Saudi Aramco Standard and
recommendation of ACI 305R and ACI 308.
• The form shall be wetted down not less than four (4) times a day until
the forms are removed. Side forms shall be removed between 12 to 24
hours after placement of concrete. After the forms are removed, the
formed surface shall receive the same curing treatment as described
In paragraph Table-1, SAES-Q-001.
• Whenever practicable, continuous water shall be initiated promptly
placing and shall be applied to the formed and unformed surface
immediately after loss of surface moisture seen. Quality of curing
water must be in accordance with SAES- 0-001, 10.

• Curing shall be maintained for a minimum of 7 days and shall comply with
Requirements of the Scope of Works and SAES·0-001, ACl-308.

5.6 Coating: -
• All concrete underground except bottom of concrete pouring in place,

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shall be coated with 2 coats of Coal tar or Bitumen coating that

conforms to APCS-3 or APCS-10. QC Inspector shall check that the
coating material is within the expiry date.
• Pre-coating inspection of the concrete structure shall be carried out by
the QC Inspector prior to the coating. The concrete surface shall be
free of sand, grease or other impurities which affect the adhesion of
coaling.
• Paint shall not be applied during adverse condition like heavy wind or
rain.

5.7 Testing Records and Reports: -

• A copy of pouring record shall be kept as file document by the

Quality Assurance and Quality Control Supervisor. All of the above is
fanned in conforming to Saudi Aramco Specification SAES-0-001 &
SAES-Q-005.
• Concrete quality test shall meet the requirement of ASTM C-31, C-
39, C- 192 & 09-SAMSS-97 and shall be performed by Saudi Aramco
approved laboratory. Records shall be kept for Saudi Aramco review.
Temperature and Slump test shall be taken for each load of fresh
concrete.
• Saudi Aramco approved Independent testing agency will be employed
to perform field and laboratory tests which shall include molded
concrete cylinders, test for slump, unit weight, air content (where air-
entrainment is required) and fresh concrete temperature in accordance
with 09-SAMSS- 097

5.8 General: -
• Request for inspection by SAUDI ARAMCO Inspection shall be

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issued 24 hours in advance for hold & witness points. RFI Form 6717
shall be used.
• Grouting shall be done in accordance with SAES-.Q-010, ASTM-C-
309, ASTM-C-109, manufacturers' product recommendation and
scope of work.
The procedure shall be as follows: -
• Remove laitance or damaged concrete with chipping hammer to level
of sound fractured aggregate to a minimum of 1inch (25 mm) of
concrete
• Construction forms higher on side to obtain a head of fluid grout

• Seal from against leakage of pre-soak later and grout.

• Pre-soak with stand water for 5 to 6 hours· minimum.

• When water cement r11//C) ratio is less than 0.4, grout shall be
continuously water cured for a minimum period of 7 days.
1- Blow out of holes, pockets of water and all deleterious matter.

2- Water shall be added as specified by the grout manufacturer lo

produce flow able grout mixture. (Ref. SAES-Q-010-6.1)
3- Use calibrated containers for water.

4- Use paddle type mixer for 5 minutes.

5- Continue mixing while slowly pouring grout power.

6- Pour grout from one side only to prevent voids.

7- Temperature of grout when placed shall be 23ac ± 3ac.

8- Cubes to be taken as perSAES-Q-010, ASTM-C-109. .

9- Curing-initially cover with plastic or damp sack after initial set, use
curing compound, SAES-0-010.

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6. Documentation:

6.1 SAIC-Q-1006 6.9 SAIC-Q-1 008 6.17 SAIC-Q-1060

6.2 SAIC-Q-1 022 6.10 SAIC-0-1010 6.18 SAIC-Q-1 045
6.3 SAIC-Q-1 023 6.11 SAIC-0-1 011 6.19 SAIC-Q-1046
6.4 SAIC-0-1 024 6.12 SAIC-0-1012 6.20 SAIC-Q-1 048
6.5 SAIC-Q-1025 6.13 SAIC-Q-1013 6.21 SAIC-Q-1049
6.6 SAIC-0-1 026 6.14 SAIC-Q-1015 6.22 SAIC-H-1 002
6.7 SAIC·0-1 028 6.15 SAIC-Q-1016 6.23 SAIC-H-1003
6.8 SAIC-Q-1 007 6.16 SAIC-Q-1017 6.24 SAIC-H-1004

END OF DOCUMENT

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