PROCEDURE FOR THE CONCRETE PLANT CERTIFICATION

Owner :
PT. Energi Bayu Jeneponto

Contractor :

Project Title :
TOLO I WIND FARM PROJECT

Document No. :

Manufacture No. :

Purpose :
ISSUED FOR APPROVAL

A Issued for Approval 09-08-2017

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REVISION HISTORICAL SHEET

Rev No Date Description

A 09-08-2017 Issued for Aproval

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1 General Description

This document describes each of the factors involved in the preparation of readymixed concrete for
Wind Farm Project the Tolo 1 field in Jeneponto, South Sulawesi, Indonesia. The present procedure
is to define chronologically the steps which must be followed in order to start up the batch plant
and to certify the concretes may be used. Batching plant using dry mix. A Dry mix Concrete Plants,
also known as Transit Mix Plants, weighs sand, gravel and cement in weigh batchers via digital or
manual scales . All the ingredients then are discharged into a chute which discharges into a truck.
Meanwhile, water is either being weighed or volumetrically metered and discharged through the
same charging chute into the mixer truck.

1.1 Reference Documentation

These followings project spesifications prescribe items for of related work:
WFP-00-CO-GS-1010 General Spesification for Concrete
WFP-00-CO-WS-1009 Concrete Work Procedure
WFP-00-CO-IN-1018 Inspection & Testing Plan
1.2 Scope
These document applies to the manufacture of readymix concrete for Wind Farm Project
the Tolo 1 field in Jeneponto, South Sulawesi Indonesia.

2 ENVIRONMENTAL CONDITION AND DESIGN

2.1 Manufacturing Process And Enviromental Conditions- According to ACI 305-99

The pouring of the concrete is carried out directly from the mixing truck to A telescopic pump, to be
later placed and consolidated by the use of air vibrators. The ambient temperature range within
which the element is estimated between 24 C and 35 C, while ambient humidity exceeds 80% during
conditions that are given of constant form throughout the year. In consequently, there are no abrupt
changes that warranty special respect, except as indicated for the preparation and placement of
concrete in weather warm, according to ACI 305-99.

3 ORGANIZATION AND MATERIALS

3.1 Personnel Concrete Staff

In addition, the following work group used :

Tittle Person
Head of Batching Plant 1
Operator Batching Plant 2
Crew Batching Plant And Laboratory 5
Operator Loader 1
Operator Water Truck 1
Operator Truck Mixer 5
Mechanical 2
Electrical 1
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Quality Control on Lab 1

TOTAL 19

3.2 The Operational Equipment

The operational equipment destined for the production of concrete is shown continuation :
Batching plant type dry with a capacity of 60 m3/h of concrete compacted.
5 mixer truck with a capacity of 7 m3.
Loader
Power Generator
Water truck with pump and flow meter measurement tool.

3.3 Material
The material source is from local cement producent and local quaries that used for readymix for all
structures and should be inspected and tested with the following standards.

3.3.1 Concrete Spesifications

The concrete specification should follow these testing process and requirements

Element Test Standard

Sampling ASTM C173-12

Slump Test ASTM C143-12
Fresh Temperature ASTM C1064-12
concrete Unitary weight ASTM C138-12
Ratio Water/Cement ACI-318
Elaboration of samples ASTM C31-12
Hardened
Compression strength ASTM C39-12
Concrete

3.3.2 Fine Aggregates and coarse Aggregates

Element Item Reources

Fine Sand Material

Bili-bili river
Aggregate
Coarse Aggregate
Max Size 10- Bili-bili river
Coarse 20mm
Aggregate Coarse Aggregate
Max Size 20- Bili-bili river
30mm

3.3.3 Cement
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Element Type Resources

Type 1 Semen Tonasa

Cement
(OPC) Semen Holcim

3.3.4 Water
Element Type Resources
Clean water for Drilling on Batch plant
Water
readymix location

3.3.5 Additives
The additive thats used is Sika Indonesia Plastiment - VZ

3.4 Concrete manufacture

3.4.1 Mixing process
Most concrete is batched and mixed in a central location called a ready-mix plant and then
trucked to the desired location. This is often the best solution even for fairly small
jobs. Ready-mix plants have a wide variety of aggregate and cement that are stored under
controlled conditions, as well as good equipment for weighing and mixing. As a result, the
quality of the concrete should be high and consistent. Concrete mixing trucks can be used to
transport already-mixed concrete, or the mixing can actually be performed by the truck as it is
traveling to the site. One potential disadvantage of ready-mixed concrete is that the time
required to transport the concrete to the site may use up too much of the early period of good
workability. This can generally be handled through the use of retarding admixtures.
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4 Concrete manufacturing process

Material Control

Mix Design
1. Performed by independent laboratory
2. Approved by Engineering

Aggregate Control Cement Control

1. Source Verification 1. Source Verification and Mill Test
2. Stock Piling Report Received
- Segregation 2. Check of unloading and transfer
- Free Draining to prefent lost and contamination
- Apperance Changes
3. Mixxing of Fine Aggregate and
Coarse Aggregat
4. Sieve Analisis

Mixing Water Control

1. check monthly for clorides & Sulfates
2. check water daily

Control Of Mix Proportion

1. Aggregate moisture checks Ordering of Concrete
2. Use of prover mix and ujusment of batch weight 1. Quality Type
3. Inspection of batching plant, etc 2. Quantity / volume
4. Log of quantitaties batched concrete

Mixing and Transportation

1. Minimum Revolution on mixer
2. Maximum time in mixer

Concrete Testing
1. Slump Test Evaluation of Test Results
2. Concrete temperature 1. Quality Control Charts
3. Unitary Weight 2. Distribution of test report
4. Molding, Sampling, curing and testing
cylinder

Adjustment of Variable
1. Materials
2. Mix Design

If the current on site batching plan is not capable of doing the mass concrete especially for the wind
turbine foundation, we will combine by using the backup bathcing plan located in Bantaeng, 35 KM
from the site location. Additional truck mixers will be added due this acceleration of concreting to not
over than 16 hours. The back up batching plan will use the same materials as mentioned above and
the material will be tested for mix design and trial mix sample compressive strength tests as the
current on site batching plan procedure.

4.1 Concrete mix preparation

Before any test, a documentary check must be made in order to verify that the batch plant
is operational (calibrate and working properly) and the material which may be used in the
production of concrete are acceptable. The first process is to determine the ingredients that
will make up the concrete and their proportions. As should be apparent from the previous
section, there are many variables to consider including cement type, aggregate size and type,
amount of water, and mineral and chemical admixtures. While a good mix design can still
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result in inadequate or poor quality concrete if it is not executed correctly, a bad mix design
will of course always give poor results. Who is responsible for designing the mix depends on
the type of project. For large, publicly funded projects the responsibility for the final design
falls to a licensed civil engineer. For residential projects such as foundations and driveways it
is the private contractor, whose professional reputation is generally his only credential. For
do-it-yourself projects it is of course the homeowner who must design his own mix.
Mixing of concrete is a very important step for achieving good final properties, and one
that can be quite difficult without the right equipment. This is one of the best reasons for
using ready-mixed concrete. Mixing distributes the aggregate evenly throughout the cement
paste, ensures that all of the cement has been fully saturated in water, and removes large air
voids. In addition, mixing breaks up agglomerated clusters of cement particles and allows air
entraining admixtures to generate the correct air void system. Undermixing leaves large flaws
and thus results in inferior strength, while overmixing wastes time and energy and can
destroy entrained air voids. The lower the workability, the more mixing energy and mixing
time is required.

4.2 Transport of concrete

Transporting the concrete mix is defined as the transferring of concrete from the mixing
plant to the construction site. Keep in mind that not all concrete is mixed on the actual
construction site and could require some significant travel. This is most common for ready-
mixed concretes. The main objective in transporting concrete is to ensure that the water-
cement ratio, slump or consistency, air content, and homogeneity are not modified from their
intended states.

If the mixture of the components is realized inside the hopper of the truck mixrs, hoppers
rotational speed must be constant to ensure the mixing and homogeneity of the concrete if
pre-mixer, the concrete will be introduced into the trucks hoppers properly mixed. Once the
homogeneity of the mixture is granted in the truck, a sample will be taken to be analysed :
Elapsed time from mixing
Temperature of concrete mass and ambient
Visual appearance (if there is any segregation or anything to be noted)
Abrams cone. It is recommended to do 2 abrams cone.
Once the fresh concrete is dehydrated, add some retarder to make the slump is enough and
good for concrete pouring flow in the foundation.
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5 Quality assurance
Flowchart of the quality assurance for batch plan readymix production and quality control

5.1 Testing Plan

All the materials and the concrete output will be tested as these following standards :

Frequency
Element Test Standard
By Third Party
By Site Laboratory
Laboratory
Humidity ASTM C566-13 Each 15 days Every 2 months
Organic Material ASTM C40-11 Each 15 days Every 2 months
Sanity ASTM C88-05 1 per week Every 2 months
Can Not be
Granulometry ASTM C33-13 Every 2 months
Fine implemented
Aggregate Unitary Weight ASTM C29-09 Each 15 days Every 2 months
Specific gravity
ASTM C128-12 Each 15 days Every 2 months
and absorption
Fine Modulus ASTM C136-06 Each 15 days Every 2 months
Abrasion ASTM C131-06 Every 6 months Every 6 months
Humidity ASTM C566-13 Each 15 days Every 2 months
Can Not be
Organic Impurities ASTM C40-11 Once during project
implemented
Sanity ASTM C88-05 Every 3 months Every 3 Monthly
Can Not be
Granulometry ASTM C33-13 Every 2 months
implemented
Coarse
Can Not be
Aggregate Peso Unitario ASTM C29-09 Every 2 months
implemented
Specific Gravity Can Not be
ASTM C127-12 Every 2 months
and Absorption implemented
Reaction to lcali-
ASTM C289-07 Each 15 days Every 2 months
Aggregates
Abrasion ASTM C131-06 Monthly Every 2 months
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Chemical
Water ASTM C94-10 Every 3 months Every 3 months
acceptance
Monthly By Monthly By Cement
Blaine ASTM C204-11
Suplayer Suplayer
Cement
Monthly By Monthly By Cement
Strength ASTM C109-12
Suplayer Suplayer
Sampling ASTM C173-12 Each 50 m3 No needed
Slump Test ASTM C143-12 Every 8 m3 No needed
ASTM C1064- No needed
Temperature Every 8 m3
Fresh 12
concrete Unitary weight ASTM C138-12 1 per week No needed
Ratio No needed
ACI-318 Every 8 m3
Water/Cement
Elaboration of No needed
ASTM C31-12 Every 80 m3
samples
Hardened Compression
ASTM C39-12 10 at 7,14,28 days 6 at 28 days
Concrete strength

All these 3rd party testing plan item, contractor will inform to owner to whitness the test 3 days before
the event and the results as per contract request and some monthly on Site lab test to ensure the
quality of the batch plan product.

All concrete sample will be tested on this periode :

/ 7 days 14 Days 28 Days
On Site Laboratory 3 3 4
3rd Party Laboratory - - 6
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5.1 Project Inspection & Test Plan

Inspection and Test Plan summary described as

PROJECT INSPECTION & TEST PLAN

Discipline Legend
CIVIL AND STRUCTURE H : Hold Point A : Approval Required TPI : Third Party Inspection
Project Title : Tolo I Wind Farm Project W : Witness R : Review EBJ : Owner
Job No : p : Perform M : Monitoring PP : Pembangunan Perumahan
Description : Project Inspection and Test Plan-Site
Equipment Tag No. : - BSB : Supplier Concrete
Location : -
INSPECTION INSPECTION LEVEL
No. DESCRIPTION REFERENCE DOCUMENT ACCEPTANCE CRITERIA VERIFIED DOCUMENT
METHOD BSB PP EBJ TPI

1 CONCRETE
1.1 Project Document

a. Inspection and Test Plan Review Comply with Approved ITP Approved ITP P R R -

b. Material Certificates Review Comply with Spec Approved Material Certificates P R R -

1.2 Procedure

Concrete Work Review Comply with spec & proc. Approved Procedure P,R R,A R -

1.3 Concrete Material

a. Material Inspection
ASTM C204-11 TLO -Q-FM- 0014
1. Cement type as per specification Inspect Comply with spec. & DWG. P,R W,A W -
ASTM C109-12 &Laboratorium Report

2. Water Test Inspect ASTM C94-10 Comply with spec. Laboratorium Report P,R W,A W -

ASTM C 33 - 01 Standard Specification for TLO -Q-FM- 0013

3. Fine and Coarse Aggregate Inspect Comply with spec. P,R R,A R -
Concrete Agregat &Laboratorium Report
TLO -Q-FM- 0016
4. Slump Test Trial Mix Inspect ASTM C143-12 Comply with spec. P,R W,A W -
&Laboratorium Report

Mix Proportioning and Trial Mix & Equipment TLO -Q-FM- 0014
b. Inspect ASTM C94 Comply with spec. P,R W,A W -
Calibration &Laboratorium Report

TLO -Q-FM- 0017

c. Concrete test (compressive strength) Inspect ASTM C39-12 Comply with spec. P,R W,A W -
&Laboratorium Report

1.4 Concrete Work

d. Concrete Pouring

5. Slump Test Inspect ASTM C143-12 Comply with spec. TLO -Q-FM- 0016 P,R W W -

6. Concrete test (compressive strength test) Inspect ASTM C39-12 Comply with spec. TLO -Q-FM- 0017 P,R W,A W -

1.5 Final Inspection

Manufacturer Data Record (In-Process

a. Review Comply with Spec Fabrication Record Book P R R
Reports) duly Signed by All Parties

b. Final Inspection Inspect Comply with Spec Final Inspection Report P W R

c. Inspection Release Notice Inspect Comply with Spec IRN P H R

Prepared by, Witnessed/Reviewed by, Approved by,

PT. BUMI SARANA BETON PT. PEMBANGUNAN PERUMAHAN PT. ENERGI BAYU JENEPONTO

Print name Date Print name Date Print name Date

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5.2 Inspection Report

Inspection report form as bellow
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5.3 Fine Agregate

Agregate material should be inspected and tested and filled in the form bellow

FINE AGGREGATE

Project Title Tolo I Wind Farm Project Sub-Contractor

Job No Report No.
Client EBJ Date DD/MM/YY
Main Contractor PT. Pembangunan Perumahan (Persero) Page 1 of 2
STD REFERENCE : TESTING DATE :
MATERIAL : SAMPLING DATE :
SOURCE : PIC :
SUPPLIER : TESTING DATE :

ASTM C33 Additional Test

Sieve No. mm Weight Retain
Total Weight
% Retain Passing
min max Parameter Spec. Result
Specific Gravity
Absorption
Silt Content
Washing Loss
Sedimentation
Clay Lumps & Friable
Organic Impurities
Visual Test (Color)
Sand Equivalent

Total

Form Code : SNO-Q-FM-0013-1 Rev.1

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5.4 Mix Design Concrete

Mix Design are recorded in the form bellow

MIX DESIGN CONCRETE

Project Title Tolo I Wind Farm Project Sub-Contractor

Job No Report No.
Client EBJ Date DD/MM/YY
Main Contractor PT. Pembangunan Perumahan (Persero) Page of
DESIGN MIX :
Slump : mm
W/C Ratio :
3
Cement : Kg/m
Fly Ash : Kg/m3
3
Silica Fume : Kg/m
Fine Aggregates : %

COMPOSITION FOR 1 CuM (SSD CONDITION)

Water : L
Cement
Type : Kg
Fly Ash : Kg
Silica Fume : Kg
Admixture : L
Retarder : L
Superplasticiser : L
Other : L

AGGREGATES VOLUME
Aggregates : Kg
Sand 1 : Kg
Sand 2 : Kg
Gravel - 01 : Kg
Gravel - 02 : Kg
Gravel - 03 : Kg

Total : Ton
Density : T/CuM

Performed By Approved By Reviewed By TPI

Involvement Party
Sub-Contractor PP EBJ (If applicable)

Signature

Name
Sign Date
Job Title
Form Code : TLO-Q-FM-0014 Rev.1
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5.5 Pouring Concrete Permit

Every mixer should have Concrete pour permit and recorded in the form bellow
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5.6 Concrete Compressive Strength Test Report

Concrete sample should be tested and recorded in the form bellow

6 Revision Plan
All equipment of batching plant should be tested including equipment in laboratorium on the batch
plant.
6.1 Equipment Periodically Revision Plan
The equipment of the batching plan, truck miThis form should be signed together and equipment
should be periodically inspected on the batch plan.
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7 SHE Plan
The primary purpose of this SHE Plan is to manage the project hazards in order to minimize the
risk and to achieve the project Safety, Health and Environmental Objective. This plan is a living
document and will be kept updated as necessary to accommodate any required improvement or
any change of Projects requirements. Regarding the committed application of this SHE Plans, we
will ensure that our SHE goals are delivered.
7.1 Standard and References
All national standard and regulation regarding SHE aspects. Some international codes and standards
are either applied to support project SHE compliance.
These are some standard and references, but not limited to, as previously mentioned.
UU No.1/1970 : KeselamatanKerja
UU No.13/2004 : KeselamatandanKesehatanKerjaKontraktor
UU No.32/2009 : PengelolaanLingkunganHidup
ISO 9000 : Quality Management System
ISO - 14001 : Environmental Management System
OHSAS - 18001 : Occupational Health and Safety
ANSI : (American National Standards Institution) standard on
Personal Protection Equipment and technical design
Compliance.
NFPA : (National Fire Protection Association) standard on Fire
Protection
ASTM : (American Standard Testing & Material) on equipment testing and material
SKK Migas : All SKK Migas Regulations
Any other related and updated standard and references.
The Project activities should comply with all regulation which applied by Owner/Main Contractor.
Once the standard and references have not described in detail, common best practices completed
with approved technical justification by Owner/Main Contractor can be allowed as PT. Bumi
Sarana Beton (Kalla Group) guidelines.
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7.2 HSE Implementation

Basic philosophy of SHE implementation is nothing wants to receive any of the negative
consequences. Mainly the accident is resulted from misleading interpretation regarding the hazard
consequences.
JSA (Job Safety Analysis)
Job Safety Analysis (JSA) to be submitted to owner before the concreting start daily.
Permit To Work System
A work permit system shall be submitted to owner before the concreting start daily.
Risk Reduction Rule
It has been confirmed that lot of common practice can be implemented at Project to reduce the risk.
Several rules have been determined to be implemented in the Project. Those rules are shown in the
following details.
Record all incident, sub-standard behavior and sub-standard condition to direct superior,
instantly
Implement a valid and specified Permit To Work with required Job Safety Analysis
Wear all adequate and proper Personal Protective Equipment in the working areas
Wear a complete breathing apparatus equipment when working in a confined space
Wear proper fall-prevention equipment when working at height
Isolate electrical equipment before work and use adequate tools and protecting equipment
Prohibit the use of any open flame and spark-potential equipment in all fire hazard premises
To ensure workers to always work under heavy equipment safe zone.
Identify escape routes, marshalling areas and any emergency equipment regarding emergency
preparedness
Keep the environment tidy by dispose all waste by its criterion in adequate storage
Wear seat belts when in a moving vehicle
Extremely prohibit work under the effect of abused drugs and alcohol
Assure the project has strong and realible emergency response system we will assess and also
shall consider every high risk activites during projectactivities such as:
Lifiting Operation
All cranes and other lifting equipment shall pass premobilization inspection witnessed by SHE Group.
All cranes and other lifting equipment shall have valid certificate from DEPNAKER and or MIGAS
(during project activities) also be load tested (as per PER-05/MEN/1985, DEPNAKER Regulation
regarding lifting equipment).
As same as lifting equipment, all concerned operator shall have valid SIO (Surat Izin Operator) from
Depnaker and or MIGAS.Detail requirement for normal lifting operation , please refer to Owner/Main
Contractor procedure SNO-X-GL-012 Rigging and Crane Operation Procedure. For critical lifting
please refer to SNO-G-PL-018 Lifting Plan.
Working at Elevated Area
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Working at elevated height contains the hazard of fall. Any activity that is carried outs at elevation 2
meter or above is include in the category of working at height. Contractor shall provide protection
system to be implemented to control this hazard consists of the following:
a. Provide access and working platform that is sufficient to allow
b. Area below the elevated work shall be cleared from people access except when wire net is
provided.
c. Provide Personnel Protective Equipment for working at height such as full body harness. PT. Bumi
Sarana Beton (Kalla Group) shall provide approved full body harness with double lanyard and shock
absorbent optionally.
d. All workforces who are assigned to work at elevated area shall get induction training prior to be
released to the job. Such training shall include the safe work procedure, the procedure to use the
fall protection equipment and procedure to maintain the equipment.
e. Safety Prevention about falling from heights, shall prepare early before project activities.
Occupational Health Plan
Medical checkup will be the the most requirement to ensure the workers in this batching plan is
healthy and prevented to several contaminate desease. Health preventiveprograms related to the
question consisted in to awareness & communication program for several deseases (Malaria, AIDS,
TBC, Hepatitis and Dengue), promotion program for reproduction health and sanitation program.

7.3 Environmental Plan

We is committed to have environmental plan and concern below shall be consider when developing
environmental plan :
Polution Prevention
Source Reduction should be given the highest priority followed by Recycling/Reuse/Recovery. For
dust and exhaust of the batching plant machine it should be filtered to reduce the pollution caused.
Waste Management Plan and Waste Disposal Area
Shall have segregation program, storaging process until disposal stage. In term of waste
management concern, after segregation process, contractor shall consider further process wheter to
dispose or handled by third party. To support the above handling, it is Contractorss responsibility
and concern to dispose the waste in therecommended area around the site for disposal area after
Owner/Main Contractor approval. Once the contractor decided the waste to be handled by third
party, PT. Bumi Sarana Beton (Kalla Group) has coordinated with Dinas Kebersihan Banggai for
further action. For further reference, please see Owner/Main Contractor Procedure Rencana
Pengelolaan Limbah SNO-V-PR-001.
B3 (Bahan Berbahaya dan Beracun / Hazardous and Toxic Material) Waste
The waste such as drums / containers, oily filter, paint, solvent & thinner, used oil are subjected to
be treated in special treatment. Contractor shall treat this kind of waste by refer to PP No.85 and
No.18 1999, all related BAPEDAL regulation, or any updated relevant regulation.