Subject: Reply and comments on Sinoma email - Ref.:SOD-YRP/S23-L0158- M.

S For Mass
Concrete of Kiln Foundations

Page 5 – a) Materials

- It is not clear the division of responsibilities between sinoma and its subcontractor personnel,
please clarify who will be in charge.
- Item 3 in the table mentions “design for cement mill”, please clarify this role for site works.

Page 6 – a) Materials

Please provide a data sheet for formwork tie rod, to show tie rod + fastener tensile strength
(Attached similar product data sheet for reference).

Page 7

– b) Equipment

- 1 batch plant will not be sufficient for kiln footing casting, and this also contradicts page
19 – 8.2.5.2 – preparatory work before pouring, as to have 100 m3/hr, as this not
achievable by one batch plant.
- The work with 100 m3/hr. will necessitate having 2 working pumps + 1 backup pump for
emergencies.
- It is mentioned 5 truck mixers on the table, while at least 10 trucks will be required to
cover the 100 m3/hr.
- Also manpower will need to consider 6 trucks + 12 drivers to work o two shift to avoid
manpower exhaust and general site HSE.

– Sequencing

- No steel rebar fabrication unless sinoma review the shop drawings.

- No opening to be performed in the formwork for casting/pouring unless this is agreed by
YCC/PEG, and if found necessary it have to be done at the inner non exposed side of
the element.
- It is recommended to apply below detail for securing the bottom of the formwork,

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 - Cooling system record log or software application template to be included in the MOS.

Page 8

8.1 Pre-work

- It is mentioned that the project will use “Al-Hanaki batch plant”, and this is not sufficient
either to big foundation works or to project works.
- Construction joint material needs material submittal and approval for work sequence
prior implementation.

Page – 9

- Point 2 – steel wire to be cut by clippers not bent into footing to avoid touching the side
of forms and getting main reinforcement corroded.
- The top of foundation is included in the plant road service area, and this needs anti-wear
material to be applied, thus sinoma to provide data sheet for the proposed material for
approval.
- Earthing accessories (if embedded according to design) need to be approved, installed,
and inspected by YCC/PEG electrical team prior casting.
- Point 5 – rebar mandrel diameter according to drawings need to be respected.
- No scheme for the location of thermo-couplers/ heat sensor is available to show depth of
measurement, sinoma to include.
Note: It is recommended to increase intermediate support between the lower and upper
reinforcement layers to bear the load of workers & equipment during casting.

Page 11

8.2.3 – Installation of Circulating water-cooling system.

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The statement “Cooled method: using cooling water that is provided from Yamama cement with
temperature 28C” needs to be discussed and approved by YCC.

Page 12

8.2.4.2 – Key point formwork

- Formwork load analysis is not included, sinoma to provide. (Please refer to ACI-347 or
equivalent).
- Formwork material specification and load capacity is not included, sinoma to provide.
(Please refer to attached similar product data sheet for reference)

Page – 18

8.2.5.1 – quality control measurement

- Field inspection for approval by YCC/PEG for form work and rebar cleaning and free
from any dirt. Dust or other material is a must to release 1st concrete truck needs to be
performed jointly by sinoma and YCC/PEG.
- Construction preparation sample is requested for approval, please refer to below photos,

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 YCC – Line 1 Tunnel wall YCC – Preheater line – 2

- Bonding agent between old/new casting need to be submitted for approval.

Page – 19

8.2.5.2 – Preparatory work before concrete pouring

- Slump testing to be conducted as per relevant local standard and adjusted according to
site needs and conditions.
- Enough aggregate, sand, stone, water + admixtures shall be prepared before work start.
Concrete admixture stock shall be calculated based on maximum dose quantity
according to manufacturer data sheet to avoid material shortage during casting.
- Nightlight needs to be considered + 2 shift electricians + 2 shift safety officers + 2 3rd
party lab technicians.

Page – 20

8.2.5.2 – Preparatory work before concrete pouring

- Existing (Al-Hanaki) + Ongoing (Sinoma) batch plants need to cover YCC/PEG email
dated 20 May 2023 - Concrete production & batch plant Comments/observations and
inspection for verification is required prior casting.
- Please unify the required number for trucks (contradiction between 5 & 10 trucks page 7
& 20).
- Dry simulation test to be conducted 1-day prior casting to ensure preparation is in place
and ready.

8.2.5.3 – Concrete pouring

- Date and time should be announced 24 hours prior to casting to get all parties ready.
- Please clarify the statement “because the water supply is not sufficient”!

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 - 5 days follow-up need to be minimum 7 days as this contradict with temperature
measurement frequency (Page 30) which indicate follow up and measurement for 15
days.
- Vibration duration of 30 sec. is considerer higher than normal (i.e. 10 sec.) and may lead
to segregation.
- Air power vibrators are not practical due to hose size and weight and the limited air-
compressor outlets, it is recommended to use electrical vibrators, if not sufficient petrol
ones can be used.

Group of Concrete casting

- Work more than 8 hrs., need 2 complete shifts of all professions.

- Names and contact numbers have to be included prior each casting.
- Responsible engineer, for each casting need to be announced and communicate his
contact for easy reach when needed.
- Number of vibrators need to be minimum 6 + 2 spare units.
- 3 + 2 spare trowelling machine needs to be included.
- Concrete finishing workers need to be minimum 8, kiln 1 is about 320 m2 and one
worker can handle 55 m2.

8.2.5.4 – Concrete curing method

- PVC sheet samples need to be submitted for review and approval.

- Foam boards samples need to be submitted form review and approval. (it has to mention
the value for thermal insulation coefficient R)
- Water spray below and above the PVC sheet is mandatory.
- Daily Curing log follow up sheet to be included, please refer to YCC/PEG email dated
22-April-2023 - Concrete Quality - curing procedure, and Sinoma to assign the
responsible engineer for daily inspection jointly with YCC/PEG.

Note: MOS for curing was rejected and needs to be re-submitted after modification.

Page 25

9.2 temperature calculation

- The temperature differential is the difference between the maximum temperature at any
point – the minimum temperature at any point (i.e. ΔT – T.max – T.min (@any point for
both), and to control it the following need to be clarified,
1- how to control cooling water flow and temperature in order not to have internal thermal
cracking due to rapid cool water injection.
2- Calculation for (Δ T) differential heat between footing core and surface is not clear for us,
more clear calculation is required.

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9.3 – Temperature calculation of mass concrete

- How to ensure cooling water rate is not more than 2 C°?!.

- A procedure on how to deal if the temperature differential gets out of range need to be
included.

According to the ACI-207-1R, the maximum differential °temperature Δ T is 19 C° and not 25 C°,
so please clarify this figure.

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9.6 – construction technique of mass concrete

- It mentioned that OP cement grade 42.5 will be used, but it should be SRC cement, and
Sinoma to confirm the cement grade as far as we know it is 52.5 MP and this will
generate higher heat of hydration which need to be considered in the calculation.
- For other concrete constituent materials please refer to the design mix.
- Please clarify the statement “it is suggested to increase the anti-crack reinforcement”,
please provide a proposal for the suggested reinforcement for information.
- It is rejected to cast “600 mm”, maximum casting layer should be 30 mm.
- Please clarify according to which standard the “technical code of box and raft JGJ6” ?!.
- Figure 5.2.5-1 & 5.2.5-2 are rejected, as they will lead to segregation, concrete shear
crack and will load one side of the forms along the casting time. It is recommended to
have layers of 30 mm – 10 mm along the footing length and to be reversed from the
other direction.
- Anti- wear material needs to be applied, sinoma to provide material approval request.
- No original mix design “water removal” is allowed.
- No “grass bags” are allowed for curing, only PVC sheets are allowed, and sinoma to
submit material approval request.
- The allowed concrete temperature for pouring is 30 C° maximum and not 35 C°.
- No “surface slurry removal” is allowed, and no scratching for surface except for
construction joint location, please refer to the required surface preparation photos.