P4045zor 93 10 28 703 - e

Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)

Technical Specification Page
Title for Concrete Work 1 of 67
No. P4045ZOR-93-10-28-703 Rev. E
Engineering, Procurement, Construction, Pre-

Commissioning and Assistance during
Commissioning/Start-up/Performance Testing of the
Al-Zour Refinery Project, Kuwait
Contract No. : ZOR / EPC – 0045
Technical Specification for Concrete Work

(Unit 79, 85, 93, 98 & 99)
E 01-11-2017 Issued for Construction D.S. JANG H.W. JI I.K. LEE
D 23-03-2017 Issued for Construction D.S. JANG H.W. JI I.K. LEE
C 30-08-2016 Issued for Construction D.S. JANG H.W. JI I.K. LEE
B 04-08-2016 Issued for Construction D.S. JANG H.W. JI I.K. LEE
A 20-06-2016 Issued for Approval D.S. JANG H.W. JI I.K. LEE
O 26-04-2016 Issued for Approval B.J. KIM H.W. JI I.K. LEE
Rev. Date Revision Description Prepared by Checked by Approved by
Document Number
Project Identifier Area/Unit No. Group Code No. Document Type Sequence No.
P4045ZOR 93 28 10 703

P4045ZOR-93-10-28-703_E
No. P4045ZOR-93-10-28-703 Rev. E
Change Log
Rev. Section Change Description
1. O First Issue for Approval
A Revised as per comments
B Issued for Construction
C Issued for Construction
D Issued for Construction
E Issued for Construction
Document Holds
Section Description

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No. P4045ZOR-93-10-28-703 Rev. E
TABLE OF CONTENTS
1. GENERAL .....................................................................................................................................6
2. CODES, STANDARD AND REFERENCES ..................................................................................6

2.1 Applicable Codes and Standards. ........................................................................................6
2.2 Project Specification ............................................................................................................6
2.3 Shell Design Engineering Practices (DEPs) and PVs ..........................................................6
2.4 International Standards and Codes......................................................................................7
3. PREPARATORY WORK..............................................................................................................12
3.1 Setting out .........................................................................................................................12
3.2 Blinding concrete or building paper ....................................................................................12
3.2.1 Blinding concrete ...........................................................................................................12
3.2.2 Building paper ...............................................................................................................13
3.2.3 Concrete elements placed on steel structures ...............................................................13
4. REQUIREMENTS OF CONCRETE WORKS ..............................................................................14

4.1 Constructional and movement joints ..................................................................................14
4.2 Concrete Cover .................................................................................................................14
4.3 Spacing of bars ................................................................................................................15
4.4 Crack width control ...........................................................................................................15
4.5 Special foundations and structures ....................................................................................16
4.5.1 Foundations for small equipment ...................................................................................16
4.5.2 Liquid-retaining structures .............................................................................................16
4.5.3 Foundations and structures subject to vibration ...........................................................16
4.5.4 Foundations subject to temperature effects .................................................................16
4.5.5 Box-outs and curbs.......................................................................................................16
5. MATERIALS ................................................................................................................................16
5.1 Cement ..............................................................................................................................17
5.1.1 Cement Type .................................................................................................................17
5.1.2 Test certificate ...............................................................................................................17
5.1.3 Transport and Storage ...................................................................................................17
5.2 Blast-Furnace Slag ............................................................................................................18
5.3 Silica Fume........................................................................................................................18
5.4 Aggregates ........................................................................................................................19
5.5 Reinforcing steel ................................................................................................................20
5.6 Water .................................................................................................................................20
5.7 Concrete Mixes..................................................................................................................21
5.8 Exposure conditions ..........................................................................................................22

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5.9 Coloured Concrete for Underground Ducts .....................................................................23

5.10 Accessories .......................................................................................................................23
6. FORMWORK ..............................................................................................................................24
6.1 General .............................................................................................................................24
6.2 Removal ............................................................................................................................24
7. REINFORCEMENT WORK ........................................................................................................25

7.1 Cutting, bending and welding ...........................................................................................25
7.2 Placing ..............................................................................................................................25
7.3 Spacers .............................................................................................................................25
8. CONCRETE MEASURING, MIXING, PRODUCTION, TRANSPORTING AND WEATHER

PROVISIONS ....................................................................................................................................26
8.1 Measuring , mixing, production and transporting................................................................26
8.2 Admixtures and additions ..................................................................................................26
8.2.1 Admixtures ....................................................................................................................26
8.2.2 Additions .......................................................................................................................27
8.3 Extreme weather provisions...............................................................................................28
8.4 Heat of hydration ...............................................................................................................28
8.5 Compression Strength Test................................................................................................29
8.6 Liquid Retaining Construction ............................................................................................29
8.6.1 General .........................................................................................................................29
8.6.2 Joints .............................................................................................................................29
8.6.3 Testing ...........................................................................................................................30
9. CONCRETE PLACING ...............................................................................................................30

9.1 General .............................................................................................................................31
9.2 Specific ..............................................................................................................................31
9.2.1 Placing by a pumping method .......................................................................................31
9.2.2 Mixing time ....................................................................................................................31
9.2.3 Concrete placed in underwater structures .....................................................................31
9.2.4 Concrete joints ..............................................................................................................31
9.2.5 Concreting and inspection test plan ...............................................................................32
9.2.6 Waterstops ....................................................................................................................34
9.3 Finishing and repair ...........................................................................................................34
9.3.1 Finishing ........................................................................................................................34
9.3.2 Setting ...........................................................................................................................34
9.3.3 Repair............................................................................................................................34
9.3.4 Coating of Concrete Surfaces ........................................................................................35

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10. CURING OF CONCRETE ...........................................................................................................36

10.1 General .............................................................................................................................36
10.2 Horizontal Surfaces ...........................................................................................................36
10.3 Vertical Surfaces................................................................................................................37
11. GROUTING .................................................................................................................................38

11.1 General .............................................................................................................................38
11.2 Types of grout ....................................................................................................................38
11.2.1 Non-shrink grout ............................................................................................................38
11.2.2 Pre-stressed systems – grouting of post tensioned tendons ..........................................39
11.3 Surface preparation ...........................................................................................................39
11.3.1 General .........................................................................................................................39
11.3.2 Shims ............................................................................................................................40
11.4 Application .........................................................................................................................40
11.4.1 Grouting of rotating/reciprocating equipment ................................................................40
11.4.2 Grouting of steel structures and stationary equipment ................................................40
11.5 Field Quality Control of Grouts...........................................................................................41
12. QUALITY PLAN ..........................................................................................................................41

12.1 General .............................................................................................................................42
12.2 Production/execution quality plan ......................................................................................42
12.2.1 General .........................................................................................................................42
12.2.2 Local Conditions Production/Execution..........................................................................42
12.2.3 Testing and Reporting....................................................................................................42
12.2.4 Testing Hardened Concrete ...........................................................................................43
13. CHEMICAL-RESISTANT STRUCTURES ....................................................................................43
14. ANCHOR BOLTS, PIPE SLEEVES, BOLTS, ETC. .....................................................................44

APPENDIX 1. AGGRESSIVITY OF THE ENVIRONMENT AND RECOMMENDATIONS FOR MIX
DESIGN
APPENDIX 2. INSPECTION AND REPAIR
APPENDIX 3. TESTS
APPENDIX 4. APPLICATION CONCRETE MIXES & ADDITIONS
APPENDIX 5. CORE-LOC TECHNICAL SPECIFICATION (FOR CONCRETE WORK)

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1. GENERAL
This specification covers the technical requirements of concrete materials, placing & curing, grouting and
reinforcement work for the concrete work which will be applied for the onshore and offshore concrete
works of KNPC Al Zour Project – 045 in Kuwait.
The requirements for the concrete works shall be in accordance with Specification for the Marine Facilities
Civil Works – Part I P4001 NRP.93.10.28.001 Rev. F (P4049N-0000-BA30-DCN-0410_R4), Shell DEP
34.19.20.31-Gen(V.32) and Project Variation to Shell DEP 34.19.20.31. PV to DEP 34.19.20.31.
The project variation (Shell DEP 34.19.20.31. PV to DEP 34.19.20.31) has been prepared to define the
project-specific amendments that include additions, deletions, exceptions, and revisions to the relevant
DEP.
2. CODES, STANDARD AND REFERENCES
2.1 Applicable Codes and Standards.
All works shall be performed in accordance with the latest version of project specifications, PVs, DEPs,
and international standards and codes over precedence.
2.2 Project Specification
 P4049N-0000-BA30-DCN-0410_R4 : Specification for the Marine Facilities Civil Works – Part

I P4001 NRP.93.10.28.001 Rev. F
 P4049N-0000-BA30-DCN-0410_R4 : Specification for the Marine Facilities Civil Works – Part
II P4001 NRP.93.10.28.002 Rev. D
 P4049N-0000-BA30-DCN-0029_R3 : Site condition at time of turnover to EPC Contractor
 P4049N-0000-BA30-DCN-0046_R3 : Underground Services FEED for the new site
 P4001NRP.00.10.08.001 : Specification for Basic Engineering Design Data
 P4045ZOR-98-20-19-701 : Design basis for onshore area Unit 85, 93, 98, & 99
 P4045ZOR-93-20-28-701 : Design basis for sea Island-Substructure(Civil &
Structure works)
2.3 Shell Design Engineering Practices (DEPs) and PVs
In this Specification, reference is made to DEP specifications and standard drawings. For project use,
these referenced DEPs (specifications and drawings) shall be used in conjunction with its project
variations, as applicable.
Shell DEPs relevant to the concrete works include the following:

 DEP 30.48.60.12-Gen. : Design and installation of chemical-resistant linings for
concrete structures

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 DEP 31.29.00.10-Gen. : Installation of rotating equipment

(amendments/supplements to API RP 686)
 DEP 34.19.20.31 - Gen : Reinforced concrete structures
 DEP 34.11.00.10-Gen. : Site investigations
 DEP 34.11.00.11-Gen. : Site preparation and earthworks including tank
foundations and tank farms
 DEP 34.11.00.12-Gen. : Geotechnical and foundation engineering
 DEP 34.17.00.32-Gen. : Design and engineering of buildings
 DEP 34.24.27.31-Gen. : Reinforced concrete stacks
 P4049N-0000-DD00-VAR-0011 : Project Variation to Shell DEP 34.19.20.31
Reinforced concrete structures
2.4 International Standards and Codes
 BS 812 : Testing aggregates

 BS 882 : Aggregates from natural sources for concrete
 BS 1377 : Methods of test for soils for civil engineering purposes
 BS 1521 : Waterproof building papers
 BS 1881 : Methods of testing concrete
 BS 1881-205 : Methods of testing concrete – Part 205:
Recommendations for radiography of concrete
 BS 2690 : Methods of testing water used in industry
 BS 4449(2005) : Specification for carbon steel bars for the reinforcement
of concrete
 BS 4483 : Steel fabric for the reinforcement of concrete –
Specification
 BS 5896 : High tensile steel wire and strand for the prestressing of
concrete
 BS 8007 : Design of concrete structures for retaining aqueous
liquids
 BS 8110 : Structural use of concrete
 BS 8110-1:1997 : Structural use of concrete – Part 1: Code of practice for
design and construction
 BS 8500 : Concrete – Complementary British Standard to EN 206-
1
 EN 196 : Methods of testing cement
Part 1: Determination of strength
Part 2: Chemical analysis of cement
Part 3: Determination of setting times and soundness
Cement

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 EN 197 Part 1: Composition, specifications and conformity

criteria for common cements
Part 4: Composition, specifications and conformity
criteria for low early strength blastfurnace cements
 EN 206-1 : Concrete – Part 1: Specification, performance,
production and conformity
 EN 445 : Grout for prestressing tendons – Test Methods
 EN 446 : Grout for prestressing tendons – Grouting procedures
 EN 447 : Grout for prestressing tendons – Specification for
common grout
 EN 450-1 : Fly ash for concrete – Part 1: Definition,
 BS EN 1744-1 : Tests for Chemical Properties of Aggregates
 BS EN 10080 : Steel for the reinforcement of concrete
 BS EN 13670 : Execution of concrete structure
 BS EN 1992 : Design of concrete structure
 ACI 224R : Control of Cracking in Concrete Structures
 ACI 301 : Specifications for Structural Concrete
 ACI 308R : Guide to Curing Concrete
 ACI 318 : Building code requirements for structural concrete
 ACI 305R : Hot weather concreting
 ACI 350/350R : Environmental Engineering Concrete Structures and
Commentary
 ASTM A153 : Standard Specification for Zinc Coating (Hot-Dip) on
Iron and Steel Hardware
 ASTM A185 : Specification for Steel Welded Wire Fabric, Plain for
Concrete Reinforcement
 ASTM A497 : Specification for Steel Welded Wire Fabric, Deformed
for Concrete Reinforcement
 ASTM A 615 : Standard specification for deformed and plain carbon-
steel bars for concrete reinforcement
 ASTM A 996 : Standard specification for rail-steel and axle-steel
deformed bars for concrete reinforcement
 ASTM C31/ C31M-03a : Standard practice for marking and Curing concrete test
specimens in the field
 ASTM C 33 : Standard specification for concrete aggregates

 ASTM C 39 : Standard test method for compressive strength of
cylindrical concrete specimens
 ASTM C 40 : Standard test method for organic impurities in fine
aggregates for concrete
 ASTM C 87 : Standard test method for effect of organic impurities in

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fine aggregate on strength of mortar

 ASTM C 88 : Standard test method for soundness of aggregates by
use of sodium sulfate or magnesium sulfate
 ASTM C 94 : Standard specification for ready-mixed concrete

 ASTM C 109 : Standard test method for compressive strength of
hydraulic cement mortars (using 2-in. or [50 mm] cube
specimens)
 ASTM C 114 : Standard test methods for chemical analysis of
hydraulic cement
 ASTM C 117 : Standard test method for materials finer than 75-µm
(No. 200) sieve in mineral aggregates by washing
 ASTM C 123 : Standard test method for lightweight particles in
aggregate
 ASTM C125 : Terminology Relating to Concrete and Concrete
Aggregates
 ASTM C 127 : Standard test method for density, relative density
(specific gravity) and absorption of coarse aggregate
 ASTM C 128 : Standard test method for density, relative density
(specific gravity) and absorption of fine aggregate
 ASTM C 136 : Standard test method for sieve analysis of fine and
coarse aggregates
 ASTM C138/138M : Test Method for Density (Unit Weight), Yield, and Air
Content (Gravimetric) of Concrete
 ASTM C 142 : Standard test method for clay lumps and friable
particles in aggregates
 ASTM C143/143M : Test Method for Slump of Hydraulic Cement Concrete
 ASTM C150 : Standard Specification for Portland Cement
 ASTM C 151 : Standard test method for autoclave expansion of
Portland cement
 ASTM C173 : Standard Test Method for Air Content of Freshly Mixed
Concrete by the Volumetric Method
 ASTM C 188 : Standard test method for density of hydraulic cement

 ASTM C 191 : Standard test methods for time of setting of hydraulic
cement by Vicat needle
 ASTM C 204 : Standard test method for fineness of hydraulic cement
by air-permeability apparatus
 ASTM C 227 : Standard test method for potential alkali reactivity of
cement-aggregate combinations (mortar-bar method)
 ASTM C 232 : Standard test methods for bleeding of concrete
 ASTM C 289 : Standard test method for potential alkali-silica reactivity
of aggregates (chemical method)

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 ASTM C 295 : Standard guide for petrographic examination of

aggregates for concrete
 ASTM C 494 : Standard specification for chemical admixtures for
concrete
 ASTM C531 : Standard Test Method for Linear Shrinkage and
Coefficient of Thermal Expansion of Chemical-Resistant
Mortars, Grouts, Monolithic Surfacings, and Polymer
Concretes
 ASTM C 535 : Standard test method for resistance to degradation of
large-size coarse aggregate by abrasion and impact in
the Los Angeles machine
 ASTM C 566 : Standard test method for total evaporable moisture
content of aggregate by drying
 ASTM C579 : Standard Test Method for Compressive Strength of
Chemical-Resistant Mortars, Grouts, Monolithic
Surfacings, and Polymer Concretes
carbonate rocks for concrete aggregates (rock cylinder
method)
 ASTM C 595 : Standard specification for blended hydraulic cements
 ASTM C642 : Test Method for Specific Gravity, Absorption, and Voids
in Hardened Concrete
 ASTM C882 : Standard Test Method for Bond Strength of Epoxy-
Resin Systems Used with Concrete by Slant Shear
 ASTM C 989 : Standard specification for ground granulated blast-
furnace slag for use in concrete and mortars
 ASTM C1017 : Specification for Chemical Admixtures for Use in
Producing Flowing Concrete
 ASTM C1064 : Test Method for Temperature of Freshly Mixed Portland
Cement Concrete
 ASTM C1107 : Standard Specification for Packaged Dry, Hydraulic-
Cement Grout (Nonshrink)
 ASTM C 1152 : Standard test method for acid-soluble chloride in mortar
and concrete
 ASTM C1181 : Standard Test Methods for Compressive Creep of
Chemical-Resistant Polymer Machinery Grouts
 ASTM C 1218 : Standard test method for water-soluble chloride in
mortar and concrete
 ASTM C1240 : Standard Specification for Silica Fume Used in
Cementitious Materials
aggregates (mortar-bar method)
 ASTM C 1293 : Standard test method for determination of length
change of concrete due to alkali-silica reaction

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 ASTM C 1602 : Standard specification for mixing water used in the

production of hydraulic cement concrete
 ASTM C 1603 : Standard test method for measurement of solids in
water
 ASTM D 511 : Standard test methods for calcium and magnesium in
water
 ASTM D 512 : Standard test methods for chloride ion in water
 ASTM D 516 : Standard test method for sulfate ion in water
 ASTM D 1126 : Standard test method for hardness in water
 ASTM D1751 : Specification for Preformed Expansion Joint Filler for
Concrete Paving and Structural Construction
(Nonextruding and Resilient Bituminous Types)
 ASTM D2103 : Standard Specification for Polyethylene Film and
Sheeting
 ASTM D2628 : Specification for Preformed Polychloroprene
Elastometric Joint Seals for Concrete Pavements
 ASTM D5893 : Standard Specification for Cold Applied, Single
Component, Chemically Curing Silicone Joint Sealant
for Portland Cement Concrete Products
 ASTM D6690 : Standard Specification for Joint and Crack Sealants, hot
applied, for Concrete and Asphalt Pavements
 AASHTO T-259 : Standard Method of Test for Resistance of Concrete to
Chloride Ion Penetration
 Plant Certification Checklist :NATIONAL READY MIXED CONCRETE ASSOCIATION
(NRMCA), Certification of Ready Mixed Concrete
Production Facilities, Eighth Edition (Quality Control
Manual – Section 3)

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3. PREPARATORY WORK
3.1 Setting out
All work shall be set out accurately from datum and benchmarks. During execution the correct position,
level and alignment of all parts of the work shall be ensured at all times.
Setting out shall meet the requirements of BS 8110-1:1997 Clause 6.2.8, with the following additions:
Permitted
Item Distance
tolerance
1 Variation from the plumb In 2.50 m +/- 5 mm
In the lines and surfaces of In any story or 5.00 m +/- 5 mm

2 columns, piers, walls and arises In any 25.00 m +/- 50 mm
Variation from the level or from the

grades indicated on the drawings. In any 3.00 m +/ 5 mm
3 In any bay +/- 5 mm
Note: Sufficient slope shall cover the In any 6.00 m +/- 10 mm
tolerance to avoid water pounding.
Variation in the thickness of slabs and

4 walls
+/- 6 mm
5 Misplacement or eccentricity +/- 10 mm
3.2 Surface Preparation for Onshore Concrete Foundations
3.2.1 Blinding concrete
A layer of blinding concrete of 50 mm minimum thickness shall be placed under foundations. The blinding
layer shall be laid immediately after excavation, draining and compacting of the bed area, in order to avoid
disturbance of soil by rain or ground water.
A case of precast footings for the foundation block of wave wall and the retaining wall at the shore
connection to U85 trestle is placed on soil to mobilize the full shear strength of the underlying soil without
the blinding concrete.

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3.2.2 Building paper and concrete surface coating
All below grade concrete foundations located onshore and linked reclaimed land, shall be protected by 3
coats of bitumen (Min. DFT 1500 microns) under polyethylene sheet liner (Min. Thk. 0.25mm) conforming
to ASTM D2103. The liner shall extend a minimum of 150 mm beyond all concrete foundation edges.
In foundations, the underside of concrete, where bitumen and polyethylene sheet cannot be used, shall
also be protected against chemical attack. The blinding concrete shall be treated with Vandex or similar
approved, prior to placing the concrete. Furthermore, the rebar distribution shall be such that serviceability
flexural cracking to the underside of the foundation is limited to 0.1mm.
3.2.3 Concrete elements placed on steel structures
To avoid damage to the steel and concrete when prefabricated concrete elements are placed directly on
steel structures, a load bearing layer shall be placed between those elements. The layer material shall be
neoprene, nylon, rubber or equivalent. When applicable the material shall be chemical resistant.

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4. REQUIREMENTS OF CONCRETE WORKS
4.1 Constructional and movement joints
Where required, constructional and/or movement joints shall be provided in concrete structures and
indicated on drawing. Construction joints are described further in (8.6.2).
4.2 Concrete Cover
The minimum concrete cover in pile caps shall be 100mm. For other parts, the minimum cover on the
outer reinforcement shall be as follows:
Minimum
Description
Cover
1. Cast-in-place concrete (non pre-stressed)
 Exposed to earth with bitumen & polyethylene protection 75 mm
 Exposed to weather 50 mm
 Not exposed to weather, water, or not in contact with the ground slabs, 40 mm
walls, beams, girders, columns
 In contact with or above water, for all application 75 mm
Minimum
Description
Cover
2. Pre-cast concrete (manufactured under plant conditions)
 Exposed to earth with bitumen & polyethylene protection 75 mm
 Exposed to weather
- Wall panels 40 mm
- Other members 50 mm
 Not exposed to weather, water, or not in contact with the ground
- slabs, walls, joints 30 mm
- beams, girders, columns 40 mm
Minimum
Description
Cover
3. Pre-stressed concrete members
 Exposed to earth 75 mm
 Exposed to weather
- Horizontal surfaces 75 mm
- Non-horizontal surfaces 50 mm
 Not exposed to weather, water, or not in contact with the ground 40 mm
 For all marine concrete other than pile caps, it is required that a minimum cover of 75mm should be
applied.
 It is required that the concrete mix design should be performed with the concrete cover of minimum
75mm to ensure the design life of 50 year for U99 structures and 60 year for U98 breakwaters.

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4.3 Spacing of bars
The minimum distance between individual bars shall be not less than:
 the maximum size of coarse aggregate + 5 mm;

 the diameter of the bar;
 50 mm, whichever is larger.
The centre-to-centre distance of individual bars shall be not more than:
150 mm - for main bars in beams where bending moments are maximum
250 mm - for main bars in slabs where bending moments are maximum
- for bars perpendicular to main bars in slabs
- for distribution bars in slabs
- for bars in walls
- for mild steel stirrups in beams
300mm - for longitudinal bars in columns

- for horizontal side bars in beams
- for high-yield stirrups in beams
400 mm - for any other bars not mentioned previously, provided the cross bars are
spaced not more than 250 mm apart
In walls and floors with a thickness of 250 mm or more, reinforcing bars shall be placed on both
sides, over the full section.
In footings and foundation slabs/blocks with a thickness of 250 mm or more, reinforcing bars
shall be placed on both top and bottom, over the full section.
The space between the bars shall not exceed 250 mm. In addition, horizontal side reinforcement
shall be placed at minimum distances of 400 mm.
4.4 Crack width control
Crack width control shall satisfy the requirements of BS EN 1992-2, For Marine Structures; the Exposure
rating for Pre-stressed and Reinforced concrete shall not be less than Class XS. (refer to Design basis
for sea island, P4045ZOR-93-20-28-701_Rev.B)
Minimum Crack
Exposure Class Exposure Conditions
Width
XC2, XC3, XC4 Corrosion induced by carbonation
Corrosion induced by chlorides other than
XD1, XD2, XD3 0.3 mm
from sea water
Corrosion induced by chlorides from sea
XS1, XS2, XS3
water
For pre-stressed concrete the crack width shall be < 0.1 mm.

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In foundations, the underside of concrete foundations, where bitumen and polyethylene cannot be used,
shall also be protected against chemical attack. The blinding concrete shall be treated with Vandex or
similar approved, prior to placing the concrete. Furthermore, the rebar and rebar distribution shall be such
that serviceability flexural cracking to the underside of the foundation is limited to 0.1mm.
4.5 Special foundations and structures
4.5.1 Foundations for small equipment
Foundations for small pumps, staircases, etc. may be placed on reinforced concrete slabs or yard paving,
provided that they are properly connected to the slabs or paving and that cable trench locations are fixed.
If required, slabs or paving shall be strengthened locally.
4.5.2 Liquid-retaining structures
In addition to all other requirements for the design of structures, special precautions shall be taken
regarding the liquid tightness of liquid-retaining structures, see EN 1992-3. All liquid retaining structures
shall be water tested under atmospheric pressure conditions, unless otherwise stated.
Liquid containing construction shall comply with this specification (8.6.1).
4.5.3 Foundations and structures subject to vibration
 Design :
A detailed design and vibration analysis shall be performed in accordance with DEP
34.00.01.30-Gen.
 Isolation of foundations:
Foundations subject to vibration shall be properly isolated from adjacent structures. Combined
foundations hall also meet the requirements of DEP 34.00.01.30-Gen.
4.5.4 Foundations subject to temperature effects
Foundations and structures subject to temperature effects shall be designed for any temperature
difference that may occur in parts of structural members and/or the whole structure.
For loading due to thermal effects, see DEP 34.00.01.30-Gen.
4.5.5 Box-outs and curbs
All holes in table tops which have equipment underneath shall be closed after installation of piping,
equipment, etc. to prevent escalation of a fire which may occur under the table top because of
draught through such holes.
All edges of table top slabs shall have a curb of minimum 100 mm height to prevent liquid and
rainwater from being drained over the edge, except at locations of entrance such as staircases
and connections to other platforms. The table top slabs shall be sloped to discharge drains or
gullies provided with down spouts.
5. MATERIALS

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5.1 Cement
Cement and additions for mixing Concrete shall comply with indicated table in Appendix 4.
5.1.1 Cement Type
 Type of cement: Blast furnace cement with a slag content of > 65%(Portland cement Type Ⅰ with
GGBS of >65%) or Portland cement type II (ASTM C-150).
 The common cement shall be complied BS EN 197-1(CEM 1), as Portland cement content, and SATM
C150(Type Ⅰ).
 Cement shall be obtained from a source approved by the Company and shall not be changed without
Company approval.
5.1.2 Test certificate
A Manufacturer's test certificate, indicating the particular batch number or fabrication date, etc. shall be
submitted by the Supplier before or during the delivery of the cement.
5.1.3 Transport and Storage
The cement shall be delivered to the site in ply bags or in bulk carriers. Bags transported by sea shall be
packed in plastic. The name and brand of the manufacturer, including batch number or fabrication date,
shall be plainly marked on the bags.
The cement shall be stored in such a way that the date of manufacturing is clearly visible so that it is used
in sequence by the date of manufacture, oldest first.
The maximum height of storage of the bags shall be 2 m with a ventilated space between the floor and
lowest bags. In tropical and subtropical areas the outside of the cement storage shall be painted white.
A cement storage shall be provided with the following:
 concrete floor/waterproof walls and roof;
 ventilation in the building to prevent condensation;
 adequate drainage system;
 air-conditioning system to control the temperature between 0 °C and 40 °C.
The bulk cement shall be stored in a silo. The silo shall comply with the following:
 in hot climates the silo shall be painted in a reflective white colour;
 in all areas the temperature shall not exceed 40 °C and/or the silo shall be maintained frost-proof.
The cement shall be suitably protected during storage to avoid deterioration in quality.

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Cement which has been in storage for more than 3 months from the date of manufacture shall be tested
to verify that its quality is still in accordance with the standards referred to in Appendix 3.
The presence of lumps will lead to rejection of the cement. Cement older than 6 months shall not be used.
5.2 Blast-Furnace Slag
Blast furnace slag shall be in accordance with ASTM C989 and shall be a replacement of Minimum 65
percent by weight of the total cement for the concrete structures in contact with or above sea water.
5.3 Silica Fume
Additions other than silica fume or ground granulated blast-furnace slag (GGBS) shall not be permitted.
Silica fume shall be used as a cement replacement for below-grade concrete. Silica fume shall be in
accordance with ASTM C1240 and shall be a replacement of six (6) to eight (8) percent by weight of the
total cement. Silica fume is not required for above grade applications, except where concrete is in direct
contact with sea- water or any other corrosive environment detrimental to concrete, such as sea-water
intake basin, sea-water cooling tower, etc. Where concrete without silica fume is used for above grade
applications, columns with silica fume shall be extended up to the first construction joint above grade. Use
of silica fume is not permitted for precast wall panels and slabs on grade (building floor and paving). Also,
silica fume is not required for plain (unreinforced) concrete below grade (refer to P4049-0000-DD00-VAR-
0011_2, Reinforced concrete)
The silica fume shall originate from a single furnace and shall be fresh furnace stock not more than 3
months old at the time of dispatch from the manufacturer’s works. It shall be stored in purpose built silos
before densification and bagging. Delivery of silica fume to the concrete batching plant shall be in dry
powder form. The silica fume shall be shipped in sealed containers. The packaging shall not deteriorate
under ultra-violet exposure for a minimum of 3 months after delivery. The silica fume shall be supplied
and used in strict accordance with the manufacturer’s instructions.
Silica Fume shall be obtained from a Company approved supplier. Contractor shall provide the following
details to the Company:
 Documentation confirming that the silica fume complies with ASTM C1240.
 Manufacturer, supplier brand and source of furnace.
 Certificates of Origin, Bills of Lading, ISO Certification relating to silica fume production.
 Chemical composition of the silica fume.
 Certificates of analysis, including batch numbers and container numbers relating to each analysis.
The certificates shall bear the corporate stamp and signature of the authorized person directly
responsible for the analysis at the origination factory.
 Records of previous usage in similar environments, particularly hot climates.
 Manufacturer’s storage and use requirements.

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 Any precautions necessary for health and safety when handling.
 Confirmation that the Company has the right of access to the supplier’s works to inspect and verify
all claims made by the supplier.
 Confirmation that the supply shall be adequate to meet the anticipated peak requirement.
Supplier’s test certification shall be provided for each delivery of silica fume. Certificate shall confirm that
the silica fume complies with all requirements listed above, and shall be submitted by the contractor along
with the mix design approval.
Company shall have the right to call for tests on each delivery of silica fume, to confirm it meets the
requirements of this specification. In such cases, samples shall be provided for testing in sufficient time
to enable assessment without delaying the Contractor’s program.
5.4 Aggregates
Coarse and fine aggregates shall comply with EN 12620 or ASTM C 33.
The content of water-soluble chlorides (expressed as Cl) shall not exceed 0.02% by weight of fine
aggregates and 0.02% by weight of coarse aggregates.
The content of acid-soluble sulphates (expressed as calculated SO3 equivalent) shall not exceed 0.4 %
by wt of fine aggregates and 0.4 % by wt of coarse aggregates.
The aggregates shall be examined in accordance with ASTM C 295 to determine presence of alkali-
reactive constituents or other deleterious reactivity.
At all times, the aggregates shall be free of impurities and if not, the aggregates shall be washed
mechanically with water to remove clay, silt and fine dust.
In case of the reinforcement concrete, coarse aggregates shall be crushed stones of 20mm maximum
size. In case of mass concrete, coarse aggregate shall be crushed stones of 40mm maximum size.
Aggregates shall be tested as indicated in Appendix 3 and shall conform to the limitations in the following
tables:
 Coarse Aggregates
Coarse Aggregates (also see Appendix 3 – Tests)

Percent Maximum By
TEST STANDARD
Weight(Unless as noted)
Los Angeles abrasion loss (grading A or B) ASTM C131 40
Ratio of Los Angeles abrasion loss at 100
and 500 revolutions (100/500 revolutions ASTM C131, Note 6 0.25
value)
Clay Lumps and friable particles ASTM C142 2.0
Material finer than 75 micron ASTM C117 1.0

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Water absorption ASTM C127 2.5

As in ASTM C33,
Reactive silica ASTM C227 or C289 Appendix XI
Chlorides (water soluble) BS EN 1744-1 0.02
Sulphates (acid soluble) BS EN 1744-1 0.40

Magnesium Sulfate soundness loss
ASTM C88 8.0
(5 cycles)
 Fine Aggregates
Fine Aggregates (also see Appendix 3 – Tests)

Percent Maximum By
TEST STANDARD
Weight(Unless as noted)
Clay Lumps and friable particles ASTM C142 1.0
Material finer than 75 micron ASTM C117 3.0
Organic Impurities ASTM C40 Color lighter than standard
Water absorption ASTM C128 1.0
Chlorides (water soluble) BS EN 1744-1 0.02
Sulphates (acid soluble) BS EN 1744-1 0.40
5.5 Reinforcing steel
General reinforcement shall conform to ASTM A615/A615M Grade 60 (or BS 4449 Grade B500B and BS
EN 10080 for higher yield strength reinforcement).
Welded wire fabric shall conform to ASTM A185 for plain fabric and to ASTM A497 for deformed fabric or
BS 4483.
5.6 Water
The water used shall be in accordance with EN 1008 and with the following.
Only clean, fresh water free from harmful matter shall be used. It shall not contain chlorides in excess of
500 mg/kg nor sulphates in excess of 200 mg/kg.
The water shall not contain dissolved solids in excess of 2000 mg/kg.
Furthermore the water shall not contain sugars, phosphates and harmful impurities (for instance oil).

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The pH of the water shall be between 5.5 and 8.0. . Tests shall be carried out in accordance with Appendix
3.
Test water for chlorides per ASTM D512, and for sulphates per ASTM D516.
5.7 Concrete Mixes
The concrete mix design shall take into account the type of foundations, structures, elements etc. for
which it is intended.
 Concrete Grade(refer to P4001NRP 93. 10.28.002 Rev. D)
Concrete shall be in accordance with DEP 34. 19.20.31 - Gen, except as modified and supplemented
below. The requirements of Sections 2.2 and Appendix 1 of the above referenced DEP are mandatory.
The atmosphere in which the structures are to be built is aggressive, continuously chloride laden and
humid. The requirements of the DEP 34. 19.20.31 - Gen concrete specification shall therefore be modified
to the following minimum requirements (Concrete Grade based on 28day Cylinder strength).
Maximum Minimum
28day cylinder Maximum
free water cement
Application strength Aggregate Remark
cement content
(Mpa) size
ratio Kg./m3
Marine
40 0.38 450 20mm
Concrete
Onshore
30 0.40 375 20mm
Concrete
Footing block
Plain concrete 40 0.38 450 20mm & Unreinforced
wave wall
Appendix. 5
Core-Loc 40 0.38 450 20mm Core-Loc Technical
specification
Red Oxide
UG Duct 20 0.45 340 10mm
(as per Section 5.9)
Lean
20 0.55 340 20mm
Concrete
To verify whether the mix design meets the specified quality requirements, trial mixes shall be produced
(unless otherwise specified) preferably on site. For each trial mix tests shall be performed as referred to
in Appendix 3.
Special attention shall be paid to possible bleeding after placing. Trial tests, including a bleeding test in
accordance with ASTM C 232, shall be performed especially for large/thick concrete elements (e.g.
horizontal slabs, columns).
Special admixtures may be considered if bleeding cannot be controlled sufficiently by means of a standard
mix design. In general a low slump in combination with proper grading and/or the use of an air entrainer

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may prevent bleeding. EN 206-1 shall apply.
The required concrete mixes shall be designed in accordance with EN 1992 and EN 206-1, or approved
equivalent, with a designation of nominal maximum size of aggregate and workability.
Furthermore, the concrete mix shall be designed for durability taking full account of the environment to
which it will be subjected.
For all concrete, the maximum acid soluble chloride ion concentrations in hardened concrete at age 28 to
42 days contributed from all ingredients including water, aggregates, cement, and admixtures, shall not
exceed 0.15 percent by weight of cement as tested per ASTM C1152.
Water /cement ratios shall be measured based on the free water available for cement hydration with the
aggregates being in saturated surface dry (SSD) condition. Aggregate moisture content and water
absorption shall be continually measured to ensure accurate measurement of the amount of free water in
the mix.
The unit weight of fresh concrete shall not be less than 2350 kg/m3 and shall be tested as indicated in
Appendix 3 – Tests.
The air content of fresh concrete shall not exceed 2% as determined by ASTM C173 or ASTM C138. See
Appendix 3 – ‘Tests’ for testing schedule.
The slump of various concrete mixes shall be such that the concrete can be transported, placed into forms,
and compacted without segregation in accordance with Section 7 and Section 8. For concrete without a
superplasticizer admixture (plain concrete), the slump shall be 100 mm +/- 25mm at the point of delivery.
For concrete with superplasticizer (structural concrete), the slump shall be 50 mm to 100 mm before the
admixture is added and a maximum slump of 200 mm at the point of delivery after the admixture is added.
Additional Testing - The following additional test results shall be submitted for approval as part of the
concrete mix qualification (These tests are not required for plain concrete mix with a water cement ratio
of 0.45.):
 Water absorption and volume of permeable voids in hardened concrete at age 28 to 42 days shall
not exceed three (3) and seven (7) percent respectively, as tested in accordance with ASTM C642.
 The amount of water soluble ion penetrating into hardened concrete in a period of 90 days shall
not exceed 0.02 percent by weight of concrete when tested in accordance with AASHTO T-259.
The required concrete strengths the maximum water/cement ratio (WCR), additions, concrete strength
and maximum aggregate size for the application concrete structures as indicated table in the following
Appendix 4.
5.8 Exposure conditions
The environments to which concrete is exposed in service can be classified into six main exposure classes
according to EN 206-1: no corrosion or attack; corrosion induced by carbonation; corrosion induced by
chlorides other than from sea water; corrosion induced by chlorides from sea water; freeze/thaw attack
with or without de-icing agents; and chemical attack. These main exposure classes with their subdivisions

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result in a total of 18 different exposure classes.
The classification criteria and subsequent requirements for concrete exposed to chemical attack (including
recommendations for mix design related to a particular exposure class or condition) are given in Appendix
1.
5.9 Coloured Concrete for Underground Ducts
Concrete encasement for underground electrical ducts shall be colored red by adding 1 kg of red oxide
powder per 100 kg of cement. Maximum aggregate size for underground ducts shall be 10 mm.
5.10 Accessories
Pre-moulded expansion joint material shall conform to ASTM D1751.
Joint sealant materials shall conform to ASTM D6690 for horizontal joints, or ASTM D2628 for both vertical
and horizontal joints.

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6. FORMWORK
6.1 General
The formwork shall be in accordance with EN 1992 1-1.
Design, calculation and execution of formwork shall take into account climatic conditions, the expected
heat of hydration and finishing of concrete surfaces.
All edges of exposed concrete members shall have a chamfer of approximately 25 mm or 50 mm.
Formwork shall be kept clean and free from binding wire, sand, water, etc. This shall be confirmed by
inspection before pouring.
Internal form ties shall be of such a nature that no permanent metallic part has less cover than the
reinforcement.
Snap-ties or through-bolts shall not be used below ground water table. The ties shall be constructed to
permit removal of the ends or end fasteners by unskilled workmen, without causing spalling at the faces
of the concrete. Form ties shall be designed to give, on removal of the ends or end fasteners, a recess
having a maximum dimension of 50mm and a depth equal to the concrete cover specified in section 4.2.2.
Waterproof through-tie system shall be used for underground structures.
Holes left by withdrawal of tie-rods shall be filled solidly with Company approved non-shrink repair mortar,
which shall be flush with the surface.
Formwork joints should be sealed to ensure no grout loss. In particular, suitable measures should be
applied to ensure joint sealing between formwork and head of pile. The joint between permanent formwork
and side of pile at bottom of pile plug should be sealed.
6.2 Removal
The formwork of building shall be removed in accordance with DEP 34.19.20.31-Gen. The formwork of
Core-LOC shall apply with CLI standard specification.
A striking plan shall be produced, which anticipates climatic conditions, heat of hydration, strength
development, load conditions and relevant curing methods.
The following time span shall apply before formwork is removed:
Type of formwork Time span

Bottom of beams 14 days
Side of beams 28 days
Bottom of slabs 6 days
Side of slabs 21 days
Construction joints 24 hours
Vertical formwork of columns and beams 24 hours
Tank walls 48 hours

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7. REINFORCEMENT WORK
7.1 Cutting, bending and welding
Reinforcing steel shall be cut, bent and welded in accordance with EN 1992-1-1:2004 Clauses
3.2 to 3.4.
Load-bearing welded joint of reinforcing steel for transmission of the design load under operating
condition should be avoided.
Non load-bearing welded joint of reinforcing steel whose strength is not taken into account in the
design of the reinforced concrete structure shall be in accordance with ISO 17660-2 or equivalent
international standard. Reinforcing steel shall be weldable material in accordance with applicable
international standard, EN 10080 or equivalent. Welds of reinforcing steel shall only be welded by
qualified welders and each weld shall be visually inspected. Welding shall be included in the quality
plan.
7.2 Placing
Black annealed steel binding wire of approximately 1.5 mm thickness shall be used for fixing the
reinforcing material. The ends of the binding wire shall be tucked in to prevent corrosion spots in
the concrete.
7.3 Spacers
Concrete spacer blocks shall conform to the requirements of this specification. Non-concrete spacer
blocks shall only be permitted provided they do not adversely affect the strength and durability of the
concrete.

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8. CONCRETE MEASURING, MIXING, PRODUCTION, TRANSPORTING AND WEATHER

PROVISIONS
8.1 Measuring , mixing, production and transporting
The measuring, mixing, production and transporting of concrete shall be in accordance with EN 1992 and
EN 206-1. Concrete shall not be hand-mixed or re-tempered.
The Contractor shall provide full details of the fully automated concrete mixing plant(s) and devices, and
shall produce trial mixes before the permanent placing of concrete is started, to prove that the specified
concrete grade can be obtained.
The temperature of the fresh concrete can be reduced by cooling the water (by adding ice) and by storing
the aggregate under shade.
The amount of water shall be in compliance with the approved mix design. No additional water shall be
added to the mix at any time.
Ready mixed concrete suppliers shall hold a current NRMCA (National Ready Mixed Concrete Association)
Certificate of Conformance for Concrete Production Facilities.
The producer of the concrete shall furnish to the purchaser a delivery ticket in accordance with ASTM C94
or BS EN 206-1, for each load of concrete.
The addition of water after concrete is first mixed shall not be allowed.
When powder silica fume is added to concrete (for silica fume requirements, see section 8.2.2), the mixing
time shall be 50 percent greater than that of concrete without silica fume. Extra time will not be required
if silica fume is used in an approved slurry form, but maximum water- cementitious material ratio shall not
exceed the values in section 5.7 above.
8.2 Admixtures and additions
8.2.1 Admixtures
An admixture is defined as a product which is added in quantities generally not more than 5 % by mass
of the cement before or during mixing or during an additional mixing operation, causing the required
modifications to the normal properties.
Admixtures shall comply with EN 206-1 or EN 934-2, and shall comply with ASTM C 494 or EN 480.
All admixtures used to modify one or more characteristics of concrete shall be accompanied by a
certificate from an approved institute, stating:
 exact range and method of application;
 physical and chemical composition;
 positive and negative side effects;
 a recommendation on the maximum allowable quantities (as a percentage of the mass of the

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cement) to achieve the particular requirement;
 proportioning and mixing.

The admixtures shall contain no chlorides. If a retarder and plasticizer are required, only a dual-purpose
additive should be used.
The classification of admixtures shall comply with ASTM C 494 or EN 934-2.
The Contractor shall be responsible for any defective concrete that may result from the use of such
admixtures. All information regarding the admixture(s), such as certificates, concrete mix trials, test results,
etc. shall be made available to the Company.
Type G admixture (superplasticizer with retarding action) meeting the requirements of ASTM C494 and
ASTM C1017 shall be utilized in all structural concrete mixes to improve workability. Superplasticizer
content shall be adjusted according to ambient condition to provide enough workability with no
segregation when concrete is properly compacted, but shall not exceed two (2) percent by weight of
cement. Mixing shall be in accordance with manufacturer’s instructions.
Other types of admixtures will be applied with Company’s approval.
8.2.2 Additions
An addition is defined as a finely divided material that is added to the concrete in order to improve certain
properties or to achieve special properties. Examples of additions are:
 GGBS in accordance with EN 15167 or ASTM C989 (pozzolanic material, used to reduce heat
caused by hydration in mass concrete);
 silica fume (pozzolanic material used for high strength concrete) ASTM C1240;
 polymers (used for liquid tight floors and rapid repairs).

All additions used to modify or improve one or more characteristics of concrete shall be accompanied by
a certificate from an approved institute, stating:
 exact range and method of application,
 physical and chemical composition,
 positive and negative side effects,
 a recommendation on the maximum allowable quantities (as a percentage of the mass of the
cement) to achieve the particular requirement,
 proportioning and mixing.

The additions shall contain no chlorides. Trial mixing shall be executed to check their effectiveness.
The Contractor shall be responsible for any defective concrete that may result from the use of such

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additions. All information regarding the addition(s), such as certificates, concrete mix trials, test results,
etc. shall be made available to the Company.
The application maritime concrete of addition silica fume to protect the chloride ingress as indicated refer
to Appendix 4.
8.3 Extreme weather provisions
Provisions for pouring concrete in extreme weather conditions shall be made with reference to the
following standards:
For hot weather:
 ACI 305R;
 EN 13670 ; and
 CEB-FIP Model Code:1990 Clause D.14

When the ambient temperature exceeds 32°C, the concrete placement shall be in accordance with ACI
305R. The temperature of fresh concrete shall be maintained between 25°C and 30°C, and at time of
placement shall not exceed 30°C. Any concrete with a temperature in excess of 30°C at the time of
placement shall not be used.
Provisions for reducing the concrete temperature should be as follows:
 Shading of aggregates, water tank, and cement silo
 Painting white the mixing plant, trucks, water tank, and cement silo
 Insulating the water tank and supply piping
 Shading of mixing plant and trucks

During summer concreting, ice will be required as a replacement for mixing water. In certain places, this
will not reduce the concrete temperature to required levels, so night-time concreting will be necessary.
The ice making plant shall supply sufficient amount of flake ice.
8.4 Heat of hydration
The heat of hydration shall not cause a temperature differential between the interior of the concrete and
any outside face greater than 20 °C.
The temperature gradient in slabs and walls over 600 mm thick shall be verified by computer models
and trail mix test pieces. If the temperature gradient is more than 20 °C, adequate measures shall be
taken to reduce the heat of hydration (e.g. by cooling, by using insulated formwork, and/or by applying
low-heat cement, retarder, pozzolanic material, etc.).
For slabs and walls over 600 mm thick, the following items shall be required with regard to the assessment
of hydration heat:

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 A concreting plan with as few construction joints as possible.

NOTE: Construction joints are joints between cured concrete and fresh concrete.
 The performance of trial mixes with special attention to the heat of hydration and workability:
-Full size (scale 1:1) test pieces shall be cast and tested representing the actual pouring conditions.
-Temperature monitoring using thermocouples.
-Strength development versus time.
-During-the-pour observation of bleeding.
 Guidance/supervision by authorised personnel appointed by the Company.
 Protective measurements and curing to avoid crack formation; see (9).

After removal of formwork a check on crack formation, supported by taking cores if specified by the
Company.
8.5 Compression Strength Test
Samples of concrete for compression tests shall be taken each day concrete is poured for the project.
There shall be five (5) test cylinders per sample. For large, continuous pours, one sample shall be taken
for each 40 m3 or portion of each 40 m3 of concrete placed. For small pours, there shall be one (1) sample
as a minimum.
Four (4) test cylinders shall be cured under standard moisture and temperature conditions in accordance
with ASTM C31. The fifth test cylinder shall be cured in the field for a minimum period of 28 days under
conditions similar to that of the curing the main concrete, unless directed otherwise by Company. Two (2)
of the moisture cured samples shall be tested 7 days after the concrete is poured, and the remaining two
(2) shall be tested on the 28th day after the concrete is poured. The field-cured 5th sample shall be stored
and tested when directed by Company.
If the test results indicate non-compliance, the quantity of concrete represented by the results shall be
removed and replaced with concrete meeting the requirement of this specification at no additional
expense to Company. Additionally, an investigation shall be performed by Contractor to identify the cause
of non-compliance and specify corrective measures. The extent of the investigation, and contractor’s
proposed corrective measures, shall be subject to Company approval.
8.6 Liquid Retaining Construction
8.6.1 General
Liquid containing construction shall comply with this specification and ACI 350 or BS EN 1992-3.
Waterproof through-tie system shall be employed in the formwork of liquid retaining construction.
8.6.2 Joints
Joints shall be designed and constructed in accordance with ASTM D5893 and ASTM D6690. Details and

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positioning of these joints, together with the materials to be used, shall be shown on the construction
drawings.
Waterstops for joints shall be installed at the locations shown on the construction drawings. See Section
9.2.6 below for requirements of waterstops.
8.6.3 Testing
In addition to testing required in Section 12.2.3, tests shall be conducted to determine the overall water
tightness of the structure and particularly the joints, in accordance with ACI 350/350R.
The structure under test shall be filled to the designed level with potable water, and shall remain for a 7
day period to allow for absorption of water. The exposed faces shall be inspected for leaks during this
period. Any defect shall be corrected, by an approved method. This could involve demolition and
rebuilding, or lining the structure in case of leaks at the joints.
9. CONCRETE PLACING

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9.1 General
The placing of concrete shall be in accordance with the appropriate clauses of EN 1992 with the
following pre-concreting operations:
 A concreting and inspection test plan including all actions to be dealt with relevant to the execution.
 The initial testing of concreting by trial casting, documented before the start of execution.
 Completion of all preparation works, inspected and documented.
 If concrete is placed directly against rock or ground, the fresh concrete shall be protected against
intermixing and water suction (blinding concrete, building paper) according to (3.4.1 and 3.4.2).
 Ground, rock, formwork or structural parts in contact with the section to be cast shall have a
temperature which does not result in freezing of the concrete before it has sufficient strength to
resist the effects of freezing (in general > 5 N/mm²).
 If the ambient temperature is expected to be high (hot weather concreting) at the time of casting or
in the curing period, precautions shall be taken to protect the concrete against damaging effects
(e.g. drying out or excessive shrinkage)
 If the ambient temperature is expected to be below 0 °C (cold weather concreting) at the time of
casting or in the curing period, precautions shall be taken to protect the concrete against damage
due to freezing.
9.2 Specific
9.2.1 Placing by a pumping method
For placing by pumping, the concrete mix shall be in accordance with the CEB-FIP
Model Code 1990, Appendix D.11.5. A back up plan (including facilities) shall be in place to ensure the
continuity of concrete placing in case the pump should fail.
9.2.2 Mixing time
The total time required for mixing, transportation and pouring of the concrete should in general not exceed
60 min when not agitated and 120 min when agitated. During this period the segregation of aggregates
shall be prevented and the workability shall be maintained. A mixing, transportation and pouring schedule
shall be produced.
9.2.3 Concrete placed in underwater structures
Special precautions are required when concrete is placed in underwater structures. A concrete placing
plan shall be submitted by the construction Contractor, for approval by the Company, based on trials which
demonstrate that the required quality and consistency of the concrete mix can be achieved.
9.2.4 Concrete joints

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Construction joints shall comply with EN 1992-1-1:2004 Clause 12.9.2 and with BS 8110-1:1997 Clause
6.2.9 and kickers shall be cast monolithically with beams/slabs/foundations.
Where construction joints are intended, they are to be defined on the construction drawings. Proper boding
of the joint is required in order to transfer tensile or shear stresses, and to prevent any passage of liquids.
Therefore, the surface shall be roughened to increase the bond strength and to achieve aggregate
interlock. The aggregate in the top surface of the first pour is to be exposed uniformly by removal of
laitance without loosening of the particles of aggregate or damaging the concrete surface of the first pour.
This preparation can be best achieved by pressure washing with water at an appropriate time after casting.
At the time of casting the further concrete con the construction joint, the hardened concrete shall be
saturated BUT free of surface water. Construction joints shall be at right angles to the main reinforcing
bars in the member, unless otherwise shown on the construction drawings. Stop ends for vertical joints
shall be removed as soon as it is practical without damaging the concrete face.
Additional construction joints (required because of limitation of concreting or shuttering), shall be approved
by Company. If these concrete joint surfaces to receive new concrete are more than one (1) hour old, the
concrete joint surface shall be roughened as specified in this section and primed with an approved bonding
agent prior to placement of new concrete.
The expansion joints for slabs on grade shall be provided on centers up to a maximum of 20m. These
joints shall be constructed to pass completely through the concrete section
The contraction joints for slabs on grade shall be provided on centers up to a maximum of 48 times the
slab thickness, but shall not exceed 8m. These joints shall be formed by scoring of the concrete prior to
taking its initial set, or by saw cutting within 12hours after placing.
It shall be ensured that joints are properly constructed and sealed as it is extremely difficult to repair a
failed joint. The expansion and contraction joints shall be sealed in accordance with ASTM 5893 and
ASTM D6690.
Refer to standard drawings S19.003, 19.004-P4049NRP-00-PV and 19.005-P4049NRP-00-PV for typical

paving joint details.
9.2.5 Concreting and inspection test plan
In general a concreting plan shall be used providing the following information:
A. Organisation
- Personnel
- Plant and equipment
B. Requirements
- Permits and required documents
- Description of work and planning
- Construction schedule and sequence, complete with manpower, plant and equipment
- Logistics of the concrete mixing transport and pouring

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- Relevant drawings of rebar/post-tensioned tendons
- Inserts and cast items
- Concrete placing requirements
- Formwork requirements including removal
- Re-compaction requirements
- Joint preparation requirements
- Pour abandonment procedure
C. Quality Control
Inspection Test Plan covering;
- Rebar and cover
- Inserts
- Formwork (including loading capacity, if required)
- Concrete placing
- Curing
- Removal of formwork (take loading capacity into account)
- Joint preparations
- Defects
D. Safety, Health and Environmental issues
- Construction site risk inventory
- Toolbox meetings
- Safety and health risk inventory
Specific issues to be addressed in the concreting plan are:
 Placing of uniform concrete layers with a maximum thickness of 0.30 m
 Care shall be taken to avoid segregation, particularly when placing concrete in tall walls and
columns etc. Concrete shall not be dropped into place from a height exceeding one (1) meter, nor
shall it be dropped through dense reinforcing steel which could cause segregation of the coarse
aggregate, or displacement of the reinforcement or formwork.
 No transportation of concrete with vibrators.
 Pouring equipment tested and ready one day before concrete is placed.
 Re-compaction of the last poured concrete layer.

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 A regular check on the workability of the concrete during placing.
 Start of curing and protection immediately after compaction of the concrete.
 Check on concrete cover before and during placing.
 Preventative measures to avoid settlement of the formwork.
 Thorough cleaning of the formwork before the concrete is placed.
 Structural concrete shall not be cast against the earth (i.e., open excavation), as the concrete cannot
be coated afterwards
9.2.6 Waterstops
Where waterstops are called for on the construction drawings for joints, the waterstops shall be fabricated
from PVC. Waterstops shall be accurately cut, fitted, and fully integrally joined at joints and junctions, to
provide a continuous watertight diaphragm at all points. Jointing of waterstops shall be by welding in
accordance with manufacturer’s instructions. The lapping of waterstops at joints, and use of adhesives
for jointing purposes, shall not be permitted unless approved by Company. Care shall be taken at all times
to ensure that waterstops are not perforated or damaged in any way during concrete placement. Damaged
waterstops shall be replaced or repaired before embedment in concrete. Particular attention shall be given
to placement and vibration of the concrete to ensure well compacted concrete around the ribs of the
waterstops. At all joints the concrete shall be placed up to the center line of the waterstop.
9.3 Finishing and repair
9.3.1 Finishing
Top surfaces of concrete in walls, beams, buttresses and floors shall be finished to the proper level and,
if specified, to the required slopes according to BS 8110. No holes or rough patches shall remain. Surfaces
requiring subsequent plastering or tiling shall be rough-finished to provide a proper key for the finishing
layer.
9.3.2 Setting
After initial setting of the concrete, any disturbance thereon (e.g. from walking, wheeling-over or vibration
of the formwork) shall be prevented until the concrete has sufficiently hardened.
Reinforcement, anchor bolts etc. projecting from the concrete shall not be disturbed during hardening of
the concrete.
9.3.3 Repair
Touching up of concrete surfaces after the removal of formwork is not permitted until they have been
inspected and released in accordance with the quality procedures.
The repair method, including materials and the extent of the repair works to remedy the imperfections of
the concrete, shall be specified and approved for each repair case and comply with the design
requirements of the structure concerned.

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In general, cementitious repair materials shall be used based on blast furnace slag cement. Repair
materials based on other cement types shall be documented and submitted by the Contractor for approval
by the Company.
For the finishing of cones the following method shall be used, provided that the volume and surface of the
concrete are suitable for repair:
 Removal of cones without damaging surrounding concrete.
 Roughening of concrete surface inside cone hole.
 Air cleaning of surface.
 Pre wetting of concrete surface with clean water.
 Application of repair mortar.
 Compaction of repair mortar.
 Curing of repair mortar after finishing.

9.3.4 Coating of Concrete Surfaces
 Surfaces Exposed to Soil:

A waterproof barrier, to prevent direct contact between the concrete surface and surrounding soil, shall
be applied to all concrete surfaces exposed to the soil.
Coating shall be a bitumen based waterproofing sealer, subject to Company’s approval. ‘The coating shall
be applied in three layers to a total dry film thickness of 1500 microns. Surface preparation and coating
application shall be in accordance with the manufacturer’s instructions.
 Surfaces Exposed to Saline Waters:

Surfaces in the sea splash zone or in the tidal zone, and the internal faces of structures containing saline
water, shall be coated with a two component, epoxy coating as defined in Appendix 2, Section 2.5, item
A.3. Specific coating shall require approval by the Company. Surface preparation and application shall be
in accordance with the manufacturer’s instructions.
 Surfaces Above Grade

All vertical concrete surfaces, up to 300mm above grade, shall be coated with epoxy paint. Specific
coating shall be approved by the Company. Surface preparation and application shall be in accordance
with the manufacturer’s instructions.

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10. CURING OF CONCRETE
Proper curing is essential for the durability of the concrete. Curing shall be carried out to avoid premature
drying of the concrete and to provide the cement paste in the concrete with sufficient water in order to
achieve a high degree of hydration.
Curing shall be carried out in accordance with EN 206, EN 1992-1-1. Additional information can be found
in the CEB-FIP Model Code 1990, Appendix D 12.
The Company methods of curing are listed below in order of preference:
 keeping formwork in place;
 sprinkling with water (at ambient temperatures above freezing);
 placing of wet hessian, covered with plastic sheet;
 applying curing compounds.
10.1 General
Concrete shall be moist cured. Curing shall commence immediately after the finishing operation or within
two (2) hours after concrete setting, and shall continue for a minimum of 10 days.
Curing of liquid-containing structures shall continue for a minimum of 14 days.
The use of curing compounds shall be permitted only after Company approval, except for surfaces
receiving subsequent finishes.
Regular, frequent inspection shall be made of concrete being cured, to establish whether or not curing is
being performed within specification.
The curing method for hot weather concreting shall be in accordance with ACI 305R. The increase of
curing period and of thermal protection is recommended.
10.2 Horizontal Surfaces
Immediately after finishing, surface shall be covered with white polyethylene sheeting, which shall be in
contact with concrete surface, with the edges lapped or tied down to exclude air circulation. After the
concrete has stiffened, but no longer than 2 hours, the sheeting shall be removed and replaced with a
hessian, soaked with water. The sheeting shall be placed over the hessian immediately, to prevent
evaporation from the hessian. For the duration of the curing period prescribed, concrete surfaces covered
with hessian shall be visibly wet. To achieve this, the hessian shall be maintained in a permanently wet
condition using water. The water used for curing shall be of the quality specified in section 5.6, and shall
be the same temperature as the concrete being cured.

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10.3 Vertical Surfaces
Vertical timber formwork shall be draped with wet hessian as soon as concrete is placed. As soon as
formwork is removed, all surfaces shall be draped with wet hessian; covered with white polyethylene
sheeting held firmly in place along all edges; and kept continuously wet for the duration of the curing
period. For the duration of the curing period prescribed, all concrete surfaces covered with hessian shall
be visibly wet. Care shall be taken to avoid drying winds, caused by a wind tunnel arrangement of the
coverings or formwork slackened from the concrete.

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11. GROUTING
11.1 General
Grouting refers to all work to be carried out to properly fill the spaces between concrete surfaces and base
plates of equipment, steel structures or prefabricated concrete elements with mortar in order to achieve
adequate transfer of horizontal and vertical forces and to inject pre-stressed systems (tendons).
For all the grouting work, the finished concrete support surface shall be such that it does not accumulate
water.
11.2 Types of grout
All grout shall be non-shrink cementitious grout unless otherwise specified on the construction drawings
to be ‘Epoxy Grout”.
11.2.1 Non-shrink grout
A grout is regarded as non-shrink if its volume is not less than the initial volume, after hardening for 28
days. During this period the test specimens shall have been completely protected against drying,
evaporating, carbonation and exposure to temperatures outside the range 23 °C +/-3 °C.
The type and brand of non-shrink grout shall, after approval, be indicated on the drawings and/or
specification for concrete work
Contractor shall supply the Manufacturer's data sheets and certificates. The grout shall be free of chlorides
and shall have a pouring consistency. A metal-oxidising or gypsum-forming non-shrink grout shall not be
used.
Non-shrink grout shall be applied under all major steel structures and stationary, rotating and reciprocating
equipment. The selection of the type of grout for rotating and reciprocating equipment shall be in
accordance with DEP 31.29.00.10-Gen.
In general one of the following types of non-shrink grout shall be used:
 cement-based non-shrink grout, with a minimum compressive strength of 75 N/mm2;
 epoxy-based non-shrink grout, with a minimum compressive strength of 95 N/mm2.

Non-shrink cementituous grout shall be proportioned products meeting all the requirements and packaged
according to ASTM C1107, requiring only the addition of potable water.
Epoxy grout shall meet the following physical properties:
 Maximum linear shrinkage (ASTM C531): 0.080
 Maximum coefficient of thermal expansion (ASTM C531): 54 x 10-6 mm/mm/°C
 Maximum creep (ASTM C1181): 5 x 10-6 mm/mm, tested at 20°C and 60°C with 2.8 MPa applied
vertical load

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 Minimum bond strength of epoxy grout to concrete (ASTM C882): 14MPa
Compressive strength shall be tested per ASTM C579, Method B Modified (for 7 day strength)
11.2.2 Pre-stressed systems – grouting of post tensioned tendons
Tendons shall be grouted in accordance with EN 1992 (Eurocode 2), CEB-FIP

Model Code 1990 Clause 11.8 and the FIP Guide to Good Practice "Grouting of tendons in pre-stressed
concrete", 1990, BS 8110-1:1997 Clause 8.9, EN 445, EN 446 and EN 447.
The injection grout shall have at least the same properties (compressive strengths, tensile strengths, The
Contractor shall compile the type and composition (including test results and data sheets) of the injection
grout.
A QA/QC procedure shall be provided by Contractor.
The ducts of the tendons shall be dried by air blowing. The air shall be free of oil and shall have a maximum
relative humidity of 65 %. The ducts of the tendons shall be filled with injection grout and checked for
proper, complete filling. See also BS 1881-205 in this respect.
The pockets at the anchorage of the pre-stressed tendons shall be filled with concrete of at least the same
properties as the structural concrete. A modified poured (repair) concrete or gunited concrete should be
used. Surface preparation, such as removal of the laitance and the use of an approved bonding agent,
shall be considered to ensure proper bonding.
11.3 Surface preparation
11.3.1 General
Surface preparation of foundations for rotating/reciprocating equipment: For surface preparation refer to
DEP 31.29.00.10-Gen.
Special attention shall be paid to the extent of the grouting. As mentioned in DEP 31.29.00.10-Gen., the
foundation shall be sized so that grouting can be extended to 50 mm beyond the base/sole plate or the
shims. If the size of concrete foundation is greater than the base/sole plate, formwork shall be used to
match the 50 mm.
Surface preparation of foundations for steel structures and stationary equipment:
The surface of the foundation under the base plate of the object to be grouted shall be chipped and
brushed to remove the weak upper layer of the concrete, damaged concrete and any oil-soaked concrete
areas. Prior to grouting, loose concrete or dust shall be removed, preferably by compressed air.
Before grouting commences the concrete surfaces shall be soaked with clean water for 24 h, unless the
grout Manufacturer specifies otherwise (saturated surface dry quality).
All grout mortar shall be machine mixed to an even consistency. Under no circumstances shall hand
mixing be employed.
Adequate wedges and/or shim plates shall be used for levelling steel structures or stationary equipment,

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prior to grouting, to which the following shall apply:
 Shims under steel structures and equipment such as columns, vessels, heat exchangers, etc. shall
be of a machined type and need not be removed. Machined type shims need the approval of the
equipment Vendor.
 Wedges are restricted to minor steel structures, supports etc. and shall be removed.
11.3.2 Shims
The following shall apply for shims that will remain in place after grouting:
 The shim shall be embedded in a mortar bed so that the top of the shim is level in all planes.
 Shim plates shall be installed so that they will be fully embedded in and surrounded by the grout to
be installed later; the minimum cover to shim sides shall be 50 mm.
Load per shim pack shall not exceed 7 N/mm2 under the worst loading condition. In this case th
e grout shall be considered as a filling material only when calculating the aforementioned bearing
stress.
11.4 Application
11.4.1 Grouting of rotating/reciprocating equipment
For grouting of this equipment, DEP 31.29.00.10-Gen. shall apply.

Exposed cement-based grout surfaces shall be coated (with an epoxy based product) if future
contamination with lubricants is possible.
11.4.2 Grouting of steel structures and stationary equipment
The installation of the grout shall be carefully supervised.

Special attention shall be paid to prevent distortion of the item being grouted.
In general the grouting shall always be executed over the shortest dimension of the
base/sole plate and in one direction only.
Proprietary grouts shall be mixed, placed and cured in strict accordance with the grout
Manufacturer's instructions.
Vent holes should be drilled in base plates to avoid air pockets. The equipment Vendor should
be consulted for approval.
The grout shall fill all voids between the base plate or sole plate and the foundation, and shall
have full surface contact.
After hardening, wedges shall be removed and the resulting voids filled with grout. The grout
thickness shall be minimum 25 mm but shall not exceed 50 mm.
The edge of the grout shall be provided with a chamfer of approximately 25 mm.

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11.5 Field Quality Control of Grouts
The Contractor shall be solely responsible for the quality control of all the materials, installations,
workmanship, and items or installations supplied by any of the Contractor’s subcontractors or vendors.
Notwithstanding the Contractor’s responsibility for quality, the grout manufacturer shall provide a
technical representative who will be on-site to review the grouting set-up procedures and the
manufacturer’s instructions with the ones who will actually be doing the grouting. The technical
representative shall remain at the grouting site as long as required to ensure that the grout
manufacturer’s installation instructions are being followed.
12. QUALITY PLAN

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12.1 General
The Contractor shall submit a quality plan which shall comply with the EN 1992 (Eurocode 2) and shall
be based on ISO 9000 quality system requirements and EN 206-1. The quality plan shall cover quality
assurance and control and shall be divided into detailed design and production/execution plan. The
quality plan shall be subject to audit by the Company.
Contractor shall always have a qualified, dedicated and full time Concrete Quality Control Engineer
(CQCE), to ensure that concrete is properly produced, placed, cured and protected in accordance with
this specification. The CQCE shall be at least a graduate civil engineer with a minimum of 10 years
experience in QA/QC, or alternatively, approved by Company, and shall be responsible for the
maintenance and submission of all specified records. The CQCE shall not report to his own site
Construction Management but to his own Head Office Management and Company designate(s). CQCE
shall be authorized to:
 Postpone concreting operations until outstanding requirements are fulfilled.
 Reject materials or workmanship which do not conform to this specification.
 Prevent the use of equipment which could cause improper construction relative to this specification
 Report any non-compliance to Company within 24 hours, but prior to pouring of concrete, and
provide records as required by Company.
12.2 Production/execution quality plan
12.2.1 General
The Production/Execution Quality Plan shall cover all aspects related to production/execution
requirements, such as performance of tests, trial mixes, availability of certificates/data sheets,
reinforcement, sources of cement/aggregates/sand/water, workmanship, batch plant(s), storage,
transport, handling etc.
12.2.2 Local Conditions Production/Execution
The quality plan shall cover all aspects related to local conditions, such as climatic conditions, back up
facilities, spare parts, transport possibilities, storage facilities, quarries, local Suppliers/Manufactures,
test facilities (field laboratory), etc. Trial concrete mixes shall be proven to perform under local
conditions and with the equipment to be used during execution.
12.2.3 Testing and Reporting
An overview of the tests, related to the concrete works, is given in Appendix 3. The contractor shall
prepare an Inspection & Test Plan (ITP) identifying the tests, frequencies, rejection criteria and
responsibilities.
A reporting system of quality records shall be part of the quality plan. The reporting system shall record
all results obtained during testing, transporting, production, supplying, placing/pouring, finishing, curing,
striking, etc. Weather conditions shall also be recorded in the quality records.
After completion, rebound and/or ultrasonic measurements should be taken to control and verify the
concrete quality against the compliance tests and required concrete quality if there is any doubt about
the above records. The results should be recorded. Any deviation shall be reported, including the
measurements to be taken.

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12.2.4 Testing Hardened Concrete
In specific cases, for example when cracks and voids are visible, Company shall have the right to ask
for samples of any hardened concrete to be taken and tested for compliance with this specification.
The cost of tests shall be paid by Contractor. Company shall have the right to ask for removal and
replacement of concrete in non-conformance. Such replacement of concrete shall be at no cost to
Company.
Whether the tests on cored samples pass or fail, Contractor shall repair/restore the cored holes by
material/procedure approved by Company, at Contractor’s expense.
13. CHEMICAL-RESISTANT STRUCTURES

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Protection against chemicals, even very dilute solutions, shall be provided either by suitable chemical
resistant bricks or tiles or by a monolithic epoxy compound.
For details of chemical-resistant linings for concrete structures, DEP 30.48.60.12-Gen. shall apply.
14. ANCHOR BOLTS, PIPE SLEEVES, BOLTS, ETC.

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The design of the anchoring length of the anchor bolts shall be checked for maximum pull-out force.
Anchor bolts, pipe sleeves, anchor rails, inserts, bolts, etc. shall be positioned accurately, and be firmly
attached to the formwork before the concrete is poured.
If slight adjustment in the position of anchor (holding-down) bolts is required, this shall be indicated on the
base plate drawing supplied with the loading information, and it shall also be clearly indicated on the detail
foundation drawing with the method(s) to be applied.
Installed anchor bolts, etc., shall be properly protected against damage and corrosion until the
equipment/structure is permanently installed. The minimum concrete cover shall be 75 mm.
Anchor bolts shall be hot-dipped galvanized, unless otherwise noted, in accordance with ASTM A153,
Class C.
APPENDIX 1. AGGRESSIVITY OF THE ENVIRONMENT AND RECOMMENDATIONS FOR MIX

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DESIGN
1. TEST CRITERIA AND CLASSIFICATION
1.1 CLASSIFICATION
In order to classify the severity of chemical attack to concrete, the exposure shall be classified in
accordance with Table 1.
Table 1 Exposure classification
Exposure Exposure/environmental conditions Sub classes

class
1 No corrosion or attack X0
2 Corrosion induced by carbonation XC1, XC2, XC3, XC4
3 Corrosion induced by chlorides other than from sea water XD1, XD2, XD3
4 Corrosion induced by chlorides from sea water XS1, XS2, XS3
5 Freeze/thaw attack with or without de-icing agents XF1, XF2, XF3, XF4
6 Chemical attack XA1, XA2, XA3
The exposure classes follow in general the guidelines of the present national and international standards.
Reference should be made to EN 206-1, BS 8500 and CEB Design Guide "Durable Concrete Structures".
The relation between the exposure classes and the various aggressivity criteria is shown in Tables 2, 3
and 4 in the following sections.
1.2 GROUND WATER
The aggressivity to concrete, depending on the concentration of chemicals present in water, is shown in
Table 2, which gives the limiting values of deleterious substances in water of predominantly natural
composition for the assessment of the severity of chemical attack. The values stated result from tests on
groundwater as described in Appendix 2.
Table 2 Limiting values of deleterious substances in water
Limiting values for the assessment of the deleterious

substances in ground water
Degree of severity 1)
Criterion of exposure class XA1 XA2 XA3
pH value 6.5 to 5.5 5.5 to 4.5 4.5 to 4.0
CO2 mg/l aggressive 15 to 40 40 to 100 >100 up to saturation
Ammonium (NH +) in mg/l 15 to 30 30 to 60 60 to 100
4
Magnesium (Mg2+) in mg/l 300 to 1000 1000 to 3000 3000 up to saturation

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Sulphate (SO4 2-) in mg/l 200 to 600 600 to 3000 3000 to 6000
1) The degree of severity is valid for stagnant or slowly moving water under moderate climatic conditions
(e.g. Central Europe). For other locations (e.g. Middle East), where more severe environmental
conditions prevail, Table 2 shall be used only as a guide. It is dependent upon the highest degree of
severity even if it is only reached by one of the five criteria listed in lines 1 to 5. Where two or more
aggressive characteristics lead to the same class, the environment shall be classified into the next
higher class, unless a special study for this specific case proves this is not necessary.
1.3 SOIL
The aggressivity of soil to concrete is shown in Table 3.
Table 3 Aggressivity of soil to concrete
Limiting values for the assessment of the deleteriousness of soils
Degree of severity 1)
Criterion of exposure classes XA1 XA2 XA3
Acidity ml/kg >200 Not encountered in practice
2000 to 3000 3000 to 12000 12000 to 24000
Sulphate (SO 2-) in mg per kg
4
1) The degree of severity is valid for soils which are saturated at frequent intervals. It can be reduced with
decreasing permeability of the soil. If the content of sulphur from sulphides exceeds 100 mg S2- per kg air-dry soil
(more than 0.01% S2-) or if dumps of industrial waste products are concerned, the deleteriousness should be
assessed by a soil consultant.
The chemical attack is expected to be more severe at higher temperatures and at higher pressures or if the
concrete is additionally exposed to mechanical abrasion due to fast flowing water or to alternating freezing and
thawing. The severity can be assumed to be lower if the water temperature is consistently low, or if the quantities
of water are small and the water is almost motionless, as for example in soils with a permeability factor
k < 10-5 m/s.
2. REQUIREMENTS FOR CONCRETE EXPOSED TO CHEMICAL ATTACK
Depending on the aggressivity of ground water and soil, measures shall be taken to adequately protect
the concrete against deterioration.
The resistance of concrete to chemical attack largely depends on the cement content, type of cement and
impermeability of the hardened concrete.
To achieve an adequate level of impermeability, the water/cement ratio (W/C) shall be kept as low as
practicable and shall not exceed the values stated in Table 3. The concrete shall be carefully cured,
preferably by wet curing for 7 days.
2.1 CHEMICAL ATTACK
In case of aggressive conditions it shall be proven on samples derived from trial mixes that the water
penetration, determined in accordance with EN 12390-8, is less than the values shown in Table 4.

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Table 4 Water penetration
Exposure Sub class W/C Minimum cement content Water Coating

class penetration
ratio Range aggr. Dnom. = 20-32 mm
3 XS1 < 0.50 300 kg/m3 < 50 mm No
XS2 < 0.45 320 kg/m3 < 50 mm No
XS3 < 0.45 340 kg/m3 < 50 mm No
4 XD1 < 0.55 300 kg/m3 < 50 mm No
XD2 < 0.55 300 kg/m3 < 50 mm No
XD3 < 0.45 320 kg/m3 < 50 mm No
5 XF1 < 0.55 300 kg/m3 < 50 mm No
XF2 < 0.55 300 kg/m3 < 50 mm No
XF3 < 0.50 320 kg/m3 < 50 mm No
XF4 < 0.45 340 kg/m3 < 50 mm No
6 XA1 < 0.55 300 kg/m3 (1) < 30 mm No
XA2 < 0.50 320 kg/m3 (1) < 30 mm No
XA3 < 0.45 360 kg/m3 (1) < 30 mm Yes 2)

1) When SO 2- leads to exposure classes XA2 and XA3, it is essential to use sulphate-resisting cement.
4
Where cement is classified with respect to resistance, moderate or high sulphate-resisting cement should be
used in exposure class XA2 (and in exposure class XA1 when applicable) and high sulphate resisting
cement should be used in exposure class XA3.
2) In all cases of severe or very severe aggressivity the selection of the coating and/or lining systems shall be
done by specialists and in consultation with the Company.
2.2 CHLORIDE ATTACK
In order to protect the reinforcement against chloride attack, the following measures shall be taken if
concrete is exposed to a concentration of Cl > 100 mg/l.
Foundations and structures on land:

1) Cement content: 340 kg/m3 with Dnom. = 40 mm.
2) Type of cement: blast furnace cement with a slag content of > 65 %.
3) Water/cement ratio: < 0.40
4) Crack width in accordance with EN 1992 (Eurocode 2). For pre-stressed concrete the crack
width shall be < 0.1 mm.
Structures in contact with or above sea water:
1) Cement content: 360 kg/m3 with Dnom. = 40 mm
2) Type of cement: blast furnace cement with a slag content of > 65 % or Portland cement
type II (ASTM C 150).
3) Water/cement ratio < 0.40

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4) Crack width in accordance with EN 1992 (Eurocode 2). For pre-stressed concrete the crack
width shall be < 0.1 mm.
3. REPORTING
The Contractor shall seek the advice of a soil consultant in the case of extreme environmental
conditions (e.g. soils containing industrial wastes, heavy salt laden atmosphere, severe weathering
regions).
A comprehensive report shall be submitted to the Company. The report shall contain but not be limited
to the following information:
1) Test results of chemical analysis of ground water and soils in accordance
with DEP 34.11.00.10-Gen.
2) The concrete mix design and measures to be taken, based on the test results as mentioned
under 1).

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APPENDIX 2. INSPECTION AND REPAIR
1. INSPECTION
Various causes can lead to significant reduction in the designed life of a concrete structure or to
unacceptable structural safety due to material deterioration. In order to ensure that the integrity of
concrete structures is maintained, regular inspection of the state of the structures will provide the
required information to initiate measures for eventual repairs.
The implementation of inspection record systems which record the history of the various structures
will help to decide whether structures can be left untreated or be repaired. The inspection can
initially be carried out visually combined with the "rebound hammer".
If this inspection gives rise to doubt about strength or durability of a structure, the structure should
be further investigated. At this stage an expert should be consulted, especially to obtain advice on
a repair method.
The investigation may involve following test methods and their purposes.
1.1 TEST METHODS
Test method Purpose

rebound hammer (NDT) determination of strength
ultrasonic (NDT) determination of strength of weak surface
layers
core drilling (DT) determination of strength, examination for
NOTE a)
porosity
concrete composition (cement content,
W/C ratio)
phenolphthalein testing (DT) determination of depth of carbonation in situ
NOTE b)
and lab
dust sampling over various depths (DT) determination of chlorides and sulphates
NOTE c)
cover meter (NDT) determination of concrete cover and position

of rebar
X-ray investigation (NDT) determination of position and diameter of
rebar
measuring of surface potential (NDT determination of non-visible corrosion on
and DT) rebar
sampling of soil and ground water determination of aggressive components
NOTE d)
NDT = non-destructive
testing DT =
destructive
NOTE testing
a) Conclusions can be drawn on the durability of the concrete depending on:
- porosity;
- maximum size of aggregates;
- porosity of aggregates;
- cement content;

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- water cement ratio
NOTE b) To determine which part of the concrete has lost its pacifying ability, a solution of 1 g
phenolphthalein to 1 L ethanol shall be sprayed on the concrete; if the concrete colours
pink, the concrete still has its pacifying ability.
NOTE c) Dust samples shall be taken over depths 0 mm to 30 mm, 30 mm to 60 mm and 60 mm
to 100 mm. Dust samples should be taken from small cores. If dust samples are taken by
using a drill, special precautions shall be taken to collect dust from the intended depth
and to prevent contamination of the sample. If the chloride content is greater than 0.3 %
of the cement content, there is a potential danger of rebar corrosion. If the SO3 content
is greater than 4 % of the cement content, there is a potential danger of sulphate attack.
The cement content of a concrete sample shall be determined in the laboratory (typical
cement:concrete ratio is 1:6).
NOTE d) Tests on ground water:
1) pH value (ASTM D 1293)
2) Hardness (ASTM D 1126)
a) Total hardness
b) Carbonate hardness
c) Non-carbonate hardness
3) Concentration of aggressive carbon dioxide (DIN 4030, Heyer test)
4) Concentration of sulphates (ASTM D 516)
5) Concentration of chlorides (ASTM D 512)
6) Concentration of magnesium (ASTM D 511)
7) Concentration of sulphides (DIN 4030)
8) Concentration of ammonium (ASTM D 1426)
9) Potassium permanganate index (ISO 8467)
10) Ca content (ASTM D 511) Soil
samples:
1) pH value of soil (ISO 10390)
2) Sulphate content (BS 1377)
3) Sulphide content (BS 1377)
4) Chloride content (BS 1377)
For sampling and tests on ground water and soil, see DEP 34.11.00.10-Gen.
1.2 CONCRETE DEFECTS

1.2.1 General
An inspection of a concrete structure may reveal the following defects:
1) Cracks 2) Deterioration 3) Surface deposits 4) Textural defects
1.2.2 Definition of terms relating to durability and strength of concrete
a) Cracks:

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An incomplete separation into two or more parts limited to a certain depth or extending over the whole
depth of a section.
Cracks are classified by direction, width and depth and may be longitudinal, transverse, vertical,
diagonal and random. Three width ranges are suggested as follows:
fine : generally less than 0.1 mm;
medium : between 0.1 mm and 0.3 mm;
wide : over 0.3 mm.

- Pattern cracking: Cracks without a regular pattern resulting from a decrease in volume
of the material near the surface, or from an increase in volume of the material below
the surface, or both.
a) Deterioration:
Deterioration is any adverse change of normal mechanical, physical and chemical properti
es either on the surface or in the whole body of concrete.
- Disintegration: deterioration into small fragments or particles due to any cause.

- Pop-out: the breaking away of small portions of a concrete surface due to internal pressure
which leaves a shallow, typically conical, depression.
- Scaling: local flaking or peeling away of the near-surface portion of concrete or mortar.
- De-moulding: adherence of concrete skin to the mould.
- Spall: a fragment, usually in the shape of a flake, detached from a larger mass by a blow,
by the action of weather, fire, pressure (rear corrosion), or expansion within the large mass.
- Dummy area: area of concrete surface which resounds hollow when struck.
b) Surface deposits:
- Exudation: a liquid or viscous gel-like material discharged through a pore, crack or opening
in the surface.
- Encrustation: a crust or coating, generally hard, formed on the surface of concrete or
masonry.
- Stalactite: a downward pointing formation, hanging from the surface of concrete, shaped
like an icicle.
- Dusting: the development of a powdered material at the surface of hardened concrete.
- Corrosion/Rust stains: disintegration of deterioration of concrete or reinforcement by
chemical or electrochemical attack.
c) Textural defects:
- Sand streak: streak in surface of formed concrete caused by bleeding or over-vibration.
- Honeycomb: voids left in concrete due to failure of the mortar to effectively fill the spaces
among coarse aggregate particles.
-
1.2.3 Cause of defects
Possible causes of defects are:
- impact;
- overloading;
- fire;
- structural movement;
- lack of durability of the concrete by e.g. incorrect cement content or type of cement;
- frost;
- chemical attack;
- electro-chemical attack;
- bad workmanship: insufficient compacting and concrete cover.

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SUMMARY OF TYPES OF DEFECTS IN RELATION TO POSSIBLE CAUSES
TYPE OF DEFECT
Cracking Deterioration Surface deposits Textural defects
POSSIBLE CAUSES Cracks Pattern Disinteg- Pop- Scaling Spalling Dummy Exuda- Encrus- Stalac- Dusting Rebar Rust Sand Honey-
(deep) cracking ration outs tion tation tite corro- stains streak combing
surface sion
Chemical influences
Carbonation X X
Chloride attack X X
Acids attack (soft water) X X X
Alkali aggregate reaction X X X X X
Sulphate attack X X
Physical influences
Fire X X X X
Frost X X X X
Leaching of lime X X
Mechanical influences
Overloading X
Differential settlements X
Impacts, explosions X X
Execution
Not properly vibrated X X
Not properly cured X X
Too high w/c ratio X X X
Excessive withdrawal of
X X X X
mixing water
Engineering
Too little concrete cover X X X
Too small rebar distances X X
Insufficient reinforcement X
Obstruction or deformation X

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2. REPAIR METHODS
2.1 DEFECTS AND REPAIR METHODS
The repair methods are specified in sections (2.2), (2.3) and (2.5) of this Appendix. The following
table gives an indication of the relation between defect and most suitable repair method by
referencing to the relevant sections.
- Cracks active - seal off with sheet or use joint sealer
- Cracks not originated by corrosion and not active:
a) deep cracks - (2.3)

b) pattern cracking - if cracks are limited to surface (2.4)
c) active cracks - because of varying temperature gradients, fill up
with elastic sealant
- Disintegration - sulphate attack or alkali reaction from the inside:

dependent on the severity or total replacement
- Pop-outs - (2.2d) + (2.4)
- Scaling - (2.4)
In case of surface attack by acids or sulphates, depth of

penetration to be established carefully, re-installation of
concrete may be required, resulting in enlarged cross
sections by means of (2.2) + (2.5)
- Spalling - (2.2) (either a, b or c) + (2.4)
- Dummy area - (2.2) (either a, b, c or d)
- Exudation - (2.4)
- Encrustation - (2.4)
- Stalactite - If the formation of stalactites is the result of

crack formation then (2.3), otherwise (2.4)
- Dusting - (2.4)
If dusting is caused by leaching of lime, determine depth

of dusting (2.2) (either a, b or d)
- Rebar corrosion - (2.2) (either a, b, c or d)
- Rust stains - (2.2) (either a, b, c or d)
- Sand streak - Depending on depth (2.2) (either a, b or d)
- Honeycombing - Depending on extent (2.2) (either a, b or d)
- Blow holes - (2.2d)

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2.2 REINSTATEMENT OF CONCRETE Preparation

before reinstatement of concrete:
In general loose particles shall be removed from the surface which has to be repaired; then the
surface must be thoroughly cleaned and wetted with water before repairing.
If the defect is attributed to ingress of chlorides the deteriorated concrete shall be removed to 30 mm
behind the existing rebar. In case of carbonation only the carbonated concrete shall be removed.
The rebar shall be thoroughly cleaned and treated with an anti-corrosive material.
The Company techniques for reinstatement of concrete are guniting, casting a new section,
prepacking, and cement-based and resin-based mortar patching.
a) Guniting is the technique most likely to achieve a technically satisfactory repair. Concrete
repair specialists have developed small equipment capable of carrying out local repair with
gunite. Good compaction is achieved with guniting, but skill is needed to ensure that the
compaction behind the reinforcement is good enough. Rebounding material can get trapped,
giving a lean, "no fines" mix at this vulnerable position. Almost no formwork is needed,
overhead repair is possible and fast progress can be achieved. Guniting can be used both for
reinstatement of spalled areas of concrete and for enlarging the cover generally over the area
of a concrete element.
b) Casting a new face onto concrete members.
This is most appropriate for walls or columns and in cases where exposure of steel is general
rather than local and where increase in member size is required and possible. The minimum
thickness that should be reinstated this way is normally 120 mm. The need for a high
workability mix achieving low permeability in the final condition will require the use of 10 mm
maximum size rounded aggregate with a super plasticizer in the mix. Shuttering and vibration
techniques are critical.
c) Pre-packing.
The method consists of placing well graded aggregates (maximum size 16 mm) between
formwork and pressure grouting of the voids between the aggregates with a sand cement
mortar.
It is a clean repair method, especially suitable for column repair in situations where guniting
causes too much mess or is impossible due to lack of space.
d) Patching-up with non-shrink ready mixed cement based mortar suitable for local repair up to
depths of approximately 40 mm, mainly for repairing of concrete of which the cover to rebar
is damaged. No formwork is required. A cement-rich mortar is essential.
If only local repair is required, it is advantageous to apply resin based mortars.
The mortars to be used are ready mixed dry pack. Often super plasticizers and/or polymers
are added in the mixing water or in the dry premix.
2.3 INJECTION OF CRACKS
Cracks wider than 0.2 mm should be injected with epoxy resin. Resins can be injected into even
finer cracks (e.g. 0.1 mm) using modern techniques now available.
Restoration of full structural properties is possible provided that the causes of cracking have
been removed. If not, further cracking is likely to occur adjacent to the old.
2.4 SURFACE TREATMENT
An overall surface treatment may be required, both to improve the appearance of the concrete and to
assist in preventing further deterioration. This surface treatment may entail e.g. grit blasting, and
local patching followed by the application of a coating.

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2.5 COATINGS FOR MAINTENANCE AND REPAIR APPLICATIONS

A. Marine structures
The following coatings should be applied:
1. Underside of structures not directly exposed to sunlight
a) Blown asphalt bitumen.
Mixture of: - Mexphalte R 85/25 – 60 % by wt and high aromatic white spirit – 40 %
by wt
Surface preparation:
1) Remove laitance from repaired concrete by light blast sweeping.
2) Clean all existing surfaces by blasting.
Application on repaired or existing concrete:
1) For surface preparation, see above.
2) Apply by brush or spray two layers of above blown asphalt bitumen mixture to a total
dry film thickness of 300 µm.
b) Flintkote (waterproofing sealer)
Application on repaired concrete or existing concrete in accordance with the
Manufacturer’s requirements:
1) For surface preparation, see above.
2) Apply by brush or spray priming layer (1 part of Flintkote to 5 parts water).
3) Apply by brush or spray, two layers of Flintkote to a total dry film thickness of 750
µm.
2. Parts of structures exposed to sunlight
For coating system, surface preparation and application refer to 1. above. Since this coating
system is not resistant to sunlight, a finishing coat of two layers bituminous aluminium paint
to a total dry film thickness of 70 µm shall be applied.
Application over the blown asphalt bitumen layer after 1 to 2 weeks.
Alternatively the coating system 1.b) Flintkote (waterproofing sealer) can be applied.
If required for cosmetic reasons a finishing coat of the aforementioned bituminous
aluminium paint can be applied after 3 to 4 weeks.
3. Parts of structures between mean low water level and high high water level, so-called splash
zone.
a) Two component, solventless epoxy coating which can be applied on wet concrete surface.
1) For surface preparation, see 1).
2) Apply by brush or roller three layers to a total dry film thickness of 1 mm.
In general, concrete areas below "mean low water level" need no further protection by a coa
ting.

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B. Coatings for concrete plant structures

The following coatings should be applied:
a) Epoxy based
1) For surface preparation see below.
2) Apply by brush, roller or spray an epoxy-based priming layer.
3) Apply by brush, roller or spray two or more layers of epoxy-based paint to a total dry
film thickness of 250 µm to 600 µm.
b) Polyurethane based
2) Apply by brush, roller or spray a polyurethane or other suitable priming layer.
3) Apply by brush, roller or spray two or more layers of polyurethane based paint to a total
dry film thickness of 200 µm.
c) Silicate based
2) Apply by brush, roller or spray a silicone or siloxane based priming layer.
3) Apply by brush, roller or spray two or more layers of silicate based paints to a total dry
film thickness of 200 µm.
Surface preparation:
1) Remove laitance from repaired concrete by light blast sweeping.
2) Clean all existing surfaces by blasting.
The choice of coating depends on the type and severity of aggressive environments to which the
concrete is subjected.
For special applications such as basement walls, holding basins etc. a specialist sho
uld be consulted.

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APPENDIX 3. TESTS
Test Description EN or ISO Standard British Standard American Standard Frequency
Cement EN 197-1, EN 197-4 ASTM C 150

Test 1 Chemical composition EN 196-2 ASTM C 114 A/E.D.
Test 2 Compressive strength EN 196-1, EN 197-1, ASTM C 109 A/E.D.
EN 197-4
Fineness EN 196-6 , EN 197-1, ASTM C 204 A/E.D.
EN 197-4
Setting time EN 196-3, EN 197-1, ASTM C 191 A/E.D.
EN 197-4, ISO 9597
Soundness EN 196-3, EN 197-1, ASTM C 151 A/E.D.
EN 197-4, ISO 9597
Test 3 Density EN 197-1 ASTM C 188 A
Aggregates EN 12620 ASTM C 33
Test 4a Organic impurities Standard colour ASTM C 40 A/D.V./ED
Test 4b Reactive constituents solution test ASTM C 295 A
Test 5 Effect of organic impurities ASTM C 87 A/ If Required
Test 6 Soundness ASTM C 88 A/O.M./ED
Test 7 Chloride content BS EN 1744-1 Analytical analysis A/O.M./ED
Test 8 SO3 content BS EN 1744-1 Analytical analysis A/O.M./ED
Test 9 Sieve analysis BS 812 ASTM C 136 A/D/ED
Test 10 10 % fines value BS 812 A/W/D.V./ED
Test 11 Crushing value (ACV) BS 812 A/W/D.V./ED
Test 12 Impact value (AIV) or Los Angeles test BS 812 ASTM C 131 A/W/D.V./ED
ASTM C 535
Test 13 Abrasion value (AAV) or Los Angeles Test BS 812 ASTM C 131 A/W/D.V./ED
ASTM C 535
Test 14 Material < 75 µm BS 812 ASTM C 117 A/W/D.V./ED
Test 15a Potential alkali-silica reactivity ASTM C 289 A/ED
Test 15b Potential alkali reactivity (in general, e.g. cement- ASTM C 227 A /ED
aggregate combination, carbonate rocks) ASTM C 586
ASTM C 1260
ASTM C 1293

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Test Description EN or ISO Standard British Standard American Standard Frequency
Aggregates Test 16 Clay lumps content BS 812 ASTM C 142 A/W/D.V./ED

Test 17 Light weight pieces in aggregate (coal/lignite content) ASTM C 123 A/O.M./ED
Test 18 Porosity:
Sand/aggregate BS 812 ASTM C 128 A/O.M./ED
Course aggregate BS 812 ASTM C 127 A/O.M./ED
Test 19 Water content in aggregates BS 812 ASTM C 566 D/D.V./S.W.C./ED
ACI 318
Water Test 20 PH value EN 1008 Analytic A/W/ED
Test 21 Chem. analysis of water EN 1008 Analytic Chloride content per ASTM A/O.M./D.V./ED
D512 and Sulphate content
per ASTM D516
Test 22 Dissolved solids EN 1008 BS 2690 ASTM C 1602, A/T.M/ED
ASTM C 1603
Test 23 Comparison setting time ASTM C 191 If Required
Test 24 Comparison compressive strength ASTM C 109 If Required
Reinforcement BS 4449 ASTM A 615
ASTM A 996
Test 25 Purchase / delivery: BS 4449 ASTM A 615 A//E.
a) Tensile test ASTM A 996 D
b) Bend test A/E.
Trial mix Test 26 Determination of mix composition EN 206-1 and BS 8500 D.
Once
Test 27 Sieve analysis materials: EN-12620 Once
Coarse and fine aggregates
Test 28 Moisture content aggregates BS 812 Once
Test 29 Temperature fresh concrete Per batch
Test 30 Workability (initial + in time) EN 206-1 and BS 8500 Per batch
Test 31 Air content ASTM C 138 Per batch
Test 32 Water cement ratio EN 206-1 and BS 8500 Per batch

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Test Description EN or ISO Standard British Standard American Frequency

Standard
Test 33 Bleeding ASTM C 232 Per batch
Test 34 EN 206-1 and BS 8500 Minimum
Compressive strength:
of 2
3 * 1 days strength batches of
12 cubes
3 * 3 days strength
3 * 7 days strength
3 * 28 days strength
Test 35 Hydration heat – Test piece full scale: Once per
- temperature monitoring specific
- strength development in time structural
- bleeding observation element
> 600 mm
Concrete mix BS 8110
Test Mix details, target strengths EN 206-1 and BS 8500
Test 36 Slump test BS 1881 ASTM C 143 D.P.
Test 37 Mix density and cement content BS 1881 ASTM C 138 E.P. (TWICE)
Test 38 Air content BS 1881 ASTM C 173 E.P. (TWICE)
Test 39 Chloride content Calculated total Cl ASTM C 1152 A/O.M.
from individual ASTM C 1218
Test 40 constituents
Calculated total SO3 A/O.M.
SO3 content
from individual
Test 41 Compression tests on cubes/cylinders constituents Acc. EN 206-1
BS 1881 ASTM C 39 and E.P.
Test 42 Concrete mixing plant description Initiallly
Test 43 Batching weigh equipment testing Initially+1./2 weekly
Test piece For

concrete
element above 600
mm thickness

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Standard
Before pouring Test 44 Cleaning formwork E.P.
Test 45 Check on concrete cover E.P.
Test 46 Surface treatment joint inspection E.P.
During pouring Test 47 Concrete layers BS 8110, D.P.
maximum 0.3 m
Test 48 Compaction D.P.
Test 49 Falling height BS 8110, E.P.
maximum 1.5 m
Test 50 Stability/settlement formwork D.P.
Test 51 Flatness/slope D.P.
Test 52 Actions with regard to environmental D.P.
weather conditions
Test 53 Recompaction D.P.
Test 54 Temperature monitoring for heat dissipation E.P.
Thickness
> 600 mm
After pouring Test 55 Finishing method and quality D.P.

Test 56 Curing (method, product) D.P.
After Test 57 Check on defects E.P.

removal Test 58 Curing compound E.P.
formwork
Test 59 Check on realised cover E.P.
Test 60 Check on realised flatness/slope E.P.

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Standard
Temperature Test 61 EN 206-1 and BS 8500 ASTM C 1064
The temperature of all constituents of the mix and the mix proper shall be recorded D.P.
Q.C. Test 62 QC programme indicating tests to be carried out initially
Test 63 Concrete materials delivery, inspection and testing E.D.
Legend:
A For approval before work commences E.D. Each Delivery T.M. Twice per Month
D Daily E.P. Each Pouring W Weekly
D.P. During Pouring O.M. Once per Month
D.V. Daily Visual S.W.C. at Sudden Weather Change
All relevant tests shall be repeated in case of change of quarry/Manufacturer/Supplier. The above tests should be part of the quality plan.

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APPENDIX 4. APPLICATION CONCRETE MIXES & ADDITIONS
NOTE
1. Binder Type Ⅰ : OPC + GGBS(>65% contents)

2. Binder Type Ⅱ : OPC + GGBS(>65% contents) + Micro Silica(6~8% contents)
3. Binder Type Ⅲ : OPC only
Cylinder
Compressive Slump
Strength Max. Minimum Max. Size
Binder Type
Water/ Binder of
Unit Application (See Note Remark
Cement Content Coarse
below) 7day 28day Before Adding After Adding
Ratio (kg/m3) Aggregate
(Mpa) (Mpa) SuperPlasticizer SuperPlasticizer
Loading Platform Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Service Platform Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Berthing Dolphin Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Mooring Dolphin Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Unit 93
Helideck Platform Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure
Marine Structures
Roadway Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm
(Pre-stressed concrete)
Pile Bent Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
CP Foundation Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structures (Below Grade)

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Cylinder
Compressive Max. Minimum Max. Size Slump
Binder Type
Strength Water/ Binder of
Approach Trestle &
Utilities Platform Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Loading Platform
(Berth) Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Sector Light Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Unit 85 Mooring Dolphin Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structures
Transfer Tower
Foundation Ⅰ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
Conveyor & Utility

FDN (sleeper) Ⅰ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
Retaining wall for

Access Ramp Ⅰ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
Wavewall
(Reinforced Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure
Concrete)
Wavewall
(Plain Concrete) Ⅰ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure (Plain Concrete)
Wavewall Footing
Block (Plain Ⅲ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure (Plain Concrete)
Unit 98 Concete)
Cap Concrete
(Offshore)
(Quay Wall) Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure(Dir. Contact sea water)
CORE-LOC Ⅰ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Concrete (Plain Concrete)
Harbour Lift Station Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
Sanitary Sewage
Manhole Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)

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Cylinder
Binder Type
COC Sump Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
AOC manhole, catch

Unit 98 basin Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
(Offshore)
Foundation
(Jib crane) Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Foundation
(Piperack, Overbrdige, Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Pipe Sleeper)
Foundation
(Piperack, Overbrdige, Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Pipe Sleeper)
Duct Bank Onshore Structure (below grade)
(Coloured Concrete) Ⅰ or Ⅱ 14 20 0.45 340 10mm 50 - 100mm Max. 200mm
Red oxide to be added (ref. Section 5.9)
Unit 98
(Onshore) Building Lift Station Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Sanitary Sewage
Manhole Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (Below grade)
AOC Sump and

Manhole Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Harbour Master’s Ⅰ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Control Tower &
Admin. / Navigation
Lighthous Ⅲ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Onshore Structure (above grade)
Unit 98
(Archi.)
Ⅰ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Other Building
Structure
Ⅲ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (above grade)

P4045ZOR-93-10-28-703_E
No. P4045ZOR-93-10-28-703 Rev. E
Cylinder
Binder Type
Wavewall
(Reinforced Concrete) Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure
Wavewall
(Plain Concrete) Ⅰ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure (Plain Concrete)
Wavewall Footing
Unit 99
Block (PlainConcrete) Ⅲ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure (Plain Concrete)
Cap Concrete
(Revetment) Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure
CORE-LOC Ⅰ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Concrete (Plain Concrete)
Onshore Pavement Ⅲ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Slab on grade
Unit 79
Offshore Pavement Ⅲ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Slab on grade
CSW : Catch Basin,
Swale, Manhole and Ⅰ or Ⅱ 20 30 0.40 375 20mm 50 - 100mm Max. 200mm Onshore Structure (below grade)
Ditch
Air release valve
Chamber Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Below Grade
Diffuser Dome Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure(Dir. Contact sea water)
Unit 88 Manhole ring Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure(Dir. Contact sea water)
Mass concrete Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm For Marker post(dir. Contact sea water)
Concrete collar Ⅰ or Ⅱ 28 40 0.38 450 20mm 50 - 100mm Max. 200mm Marine Structure(Dir. Contact sea water)
Ⅲ
COM
MON
Lean concrete 14 20 0.55 340 20mm 50 - 100mm Max. 200mm

P4045ZOR-93-10-28-703_E
No. P4045ZOR-93-10-28-703 Rev. E
APPENDIX 5. CORE-LOC TECHNICAL SPECIFICATION (FOR CONCRETE WORK)

P4045ZOR-93-10-28-703_E

P4045zor 93 10 28 703 - e

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Al-Zour Refinery Project

(Contract No. : ZOR/EPC - 0045)

Engineering, Procurement, Construction, Pre-

Contract No. : ZOR / EPC – 0045

Technical Specification for Concrete Work

E 01-11-2017 Issued for Construction D.S. JANG H.W. JI I.K. LEE

D 23-03-2017 Issued for Construction D.S. JANG H.W. JI I.K. LEE

C 30-08-2016 Issued for Construction D.S. JANG H.W. JI I.K. LEE

B 04-08-2016 Issued for Construction D.S. JANG H.W. JI I.K. LEE

A 20-06-2016 Issued for Approval D.S. JANG H.W. JI I.K. LEE

O 26-04-2016 Issued for Approval B.J. KIM H.W. JI I.K. LEE

Rev. Date Revision Description Prepared by Checked by Approved by

Technical Specification for Concrete Work

Rev. Section Change Description

1. O First Issue for Approval

A Revised as per comments

B Issued for Construction

C Issued for Construction

D Issued for Construction

E Issued for Construction

Technical Specification for Concrete Work

2. CODES, STANDARD AND REFERENCES ..................................................................................6

4. REQUIREMENTS OF CONCRETE WORKS ..............................................................................14

Technical Specification for Concrete Work

5.9 Coloured Concrete for Underground Ducts .....................................................................23

7. REINFORCEMENT WORK ........................................................................................................25

8. CONCRETE MEASURING, MIXING, PRODUCTION, TRANSPORTING AND WEATHER

9. CONCRETE PLACING ...............................................................................................................30

Technical Specification for Concrete Work

10. CURING OF CONCRETE ...........................................................................................................36

11. GROUTING .................................................................................................................................38

12. QUALITY PLAN ..........................................................................................................................41

13. CHEMICAL-RESISTANT STRUCTURES ....................................................................................43

14. ANCHOR BOLTS, PIPE SLEEVES, BOLTS, ETC. .....................................................................44

Technical Specification for Concrete Work

2. CODES, STANDARD AND REFERENCES

2.1 Applicable Codes and Standards.

2.2 Project Specification

 P4049N-0000-BA30-DCN-0410_R4 : Specification for the Marine Facilities Civil Works – Part

2.3 Shell Design Engineering Practices (DEPs) and PVs

Shell DEPs relevant to the concrete works include the following:

Technical Specification for Concrete Work

 DEP 31.29.00.10-Gen. : Installation of rotating equipment

2.4 International Standards and Codes

 BS 812 : Testing aggregates

Technical Specification for Concrete Work

 EN 197 Part 1: Composition, specifications and conformity

 ASTM C 33 : Standard specification for concrete aggregates

Technical Specification for Concrete Work

fine aggregate on strength of mortar

 ASTM C 94 : Standard specification for ready-mixed concrete

 ASTM C 188 : Standard test method for density of hydraulic cement

Technical Specification for Concrete Work

 ASTM C 295 : Standard guide for petrographic examination of

Technical Specification for Concrete Work

 ASTM C 1602 : Standard specification for mixing water used in the

Technical Specification for Concrete Work

3.1 Setting out

1 Variation from the plumb In 2.50 m +/- 5 mm

In the lines and surfaces of In any story or 5.00 m +/- 5 mm

Variation from the level or from the

Variation in the thickness of slabs and

5 Misplacement or eccentricity +/- 10 mm