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GAS QCP CIV 002 Work Procedure
GAS QCP CIV 002 Work Procedure
GAS Arabian
Concrete Work Services Co. Ltd
Dammam
TABLE OF CONTENTS
Pages
1.0 Scope 4
2.0 References 4
3.0 Definitions 4
4.0 Responsibility 4
NOTE: Where revisions affect the whole document, NO identification will be placed adjacent to the revised paragraph.
1.0 SCOPE
This Quality Control Procedure defines the type and extent of inspections to be carried out to
verify that all operations involved in installation of reinforcement, placing Concrete, Curing,
finishing, Repair and coating of Structural and Non-Structural Concrete conform to specified
requirements for the Scope of work of Contract No. 103695 KAEC IV NATURAL GAS
NETWORK.
2.0 REFERENCES
4.0 RESPONSIBILITY
Ensure compliance by all craftsmen to the content of this procedure, Quality Plan,
Inspection & Test Plan and customer standard requirement.
Ensure the correct IFC drawings, approved procedures associated with the
construction of concrete structures are available to, and used by, all personnel in
charge of the work. Ensure that all submittals required by the client are duly
approved and issued for use. Confirm construction materials are available and
comply with the project specifications.
Ensure work permits are obtained prior to commencement of any work. Checks
personnel and confirms compliance to safety requirements, such as wearing
personnel protective equipment. Check work areas for any unsafe conditions.
Liaise with the field supervisors ensuring that work is carried out in accordance
with project safety plan/procedures.
5.0 PROCEDURES
5.1.1 FBE coated / Bare reinforcing bars shall be procured and delivered to
the job site as per project specification and confirms to MTO and IFC
drawing.
5.1.2 The bars shall be cut exactly to the lengths indicated on the project bar
bending schedules using a bar cutter. Cutting torches shall not be
used for cutting re bars.
5.1.3 The cut ends of FBE coated rebar, shall be repaired with the approved
patching material.
5.1.4 All reinforcement shall be bent cold. Bars shall not be bent in a manner
that may damage the coating.
5.1.5
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GAS Arabian
Concrete Work Services Co. Ltd
Dammam
Bars shall be bent as shown on the project bending schedules. Degree
of accuracy shall be in accordance with the project specifications.
5.1.6 A mandrel (or pin) that is fabricated from, or covered with, a collar of
wood , nylon or other non-abrasive material, which will not damage the
epoxy coating, shall be used for bending.
5.1.7 Unless otherwise specified, while selecting the size of mandrel a 1:8
(rebar : bend) diameter ration shall be used for coated rebar.
5.1.9 The rebar shall be placed and firmly tied at all intersections, except
where spacing is 300 mm or less, in each direction, which case
alternate intersections shall be tied.
5.1.13 Epoxy or plastic-coated tie wire shall be used for FBE coated rebar,
and galvanized tie-wire for non-FBE coated rebar, to fasten reinforcing
bars by double wrapping with at least two full twists, unless otherwise
specified.
5.1.14 The cut ends of the tie wire shall be turned to the inside of the exposed
concrete surfaces.
5.1.17 Welded wire fabric (WWF) per ASTM A185-90A (non-FBE coated)
shall be used for slabs on grade unless otherwise indicated in the
drawings. Lapping of WWF must be equal to the spacing of cross wire
plus 50 mm. tying shall be as project requirements.
5.1.18 Finished installed rebar shall be free from oil, grease, mud, dust and
deleterious materials that may affect rebar and concrete bond.
All sleeves, inserts, anchor bolts, water stops and other embedded
items shall be installed in accordance with the design drawings and
supported against displacement.
The design of anchor bolts shall be in accordance to SAES-Q-005 and
the materials shall be in accordance to 12-SAMSS-007.
Projecting steel items (such as grating angles, slide plates, unistrut,
steel plates, etc.) which are attached to the formwork and cast at the
concrete surface shall be hot dip galvanized in accordance with ASTM
A123 or coated with the zinc rich epoxy primer in APCS-1C of SAES-
H-101. Additionally, the steel attachment, which anchors these items
to the concrete, shall be similarly galvanized or coated.
Reinforcing steel bars, anchor bolts or other steel embedments shall
not be used as the means for grounding electrical equipment and shall
not be tied to grounding neutral conductors, or any part of the lightning
protection system. Conduits, pipes and other items made from
aluminum shall not be embedded in structural concrete unless
effectively coated to prevent aluminum-concrete reaction.
A) Type, size, detail and location of embedment not shown on the
construction documents shall be submitted for review by license design
professional. – ACI 318 Para. 26.8.2a
B) Aluminum embedment’s shall be coated or covered to prevent aluminum
concrete reaction or electrolytic action between Aluminum and Steel. – ACI
318 Para. 26.8.2b
C) Pipes and Fittings not shown in the construction documents shall be design
to resist effect of Materials, Pressure, and Temperature to which they will
subjected. – ACI 318 Para. 26.8.2c
5.2.1 Handling
5.2.2 Storage
When placing re-bars, all wire bar supports, spacers and tying wire
should be coated with dielectric material.
5.3 Formworks
5.3.1 Inspection and testing of the prepared sub-grade shall have been
conducted satisfactory, prior to the construction of formworks.
5.3.2 Forms shall be fabricated with sufficient lateral and diagonal bracing,
in a way, which will resist all loads and displacement.
5.3.3 Forms shall withstand vibration and other loads occurring during the
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GAS Arabian
Concrete Work Services Co. Ltd
Dammam
construction operation.
5.3.4 Conduits, pipes and spacers between forms, rebar and other
embedment shall be properly installed and inspected before closing
forms.
5.3.5 Forms intended for elevated slabs, beams, canopies and the like
should be adequately shored. Metal frames used for shoring shall not
be loaded beyond the safe working load recommended by the
manufacturer.
5.3.6 Install forms for columns with sufficient ties and braces to prevent any
lateral movement and check for plumpness.
5.3.7 Sufficient braces, spacers and tie rods shall be used for wall
formworks to ensure that the forms and re-bar is not displaced during
concrete pouring.
5.3.8 Continuous tie rods with PVC sleeve, PVC cones and wing nuts, or
other approved supports shall be used for tightening and aligning.
5.3.9 For watertight wall enclosures, i.e. sumps and tanks, tie rods with
coupling nuts that will be installed along the center of forms with wing
nuts, or other approved supports suitable for water retaining
structures, may be used.
5.3.13 Forms should be mortar tight and paste tight for all concrete
construction to avoid loss of mortar or leakage that will cause voids in
the concrete surface. Defective forms will not be used.
5.3.14 Forms shall be thoroughly cleaned of all dirt mortar and foreign matter
and coated with appropriate oil (release agent) in accordance with the
manufacturer’s recommendation, prior to form installation. Form
release agents shall not be applied where concrete surfaces will
receive special finishes.
5.3.17 All sawdust, chips, construction debris and other extraneous materials
shall be removed prior to inspection.
5.3.18 The formworks shall be provided with adequate safe access for
workers and inspectors. Platforms and walkways shall be provided
with handrails when deemed necessary. Temporary openings shall be
provided, where interior area of formwork is inaccessible for clean out
and for inspection before concrete placement.
5.3.19 Foundation numbers will be marked on the formwork and the tag
numbers removed from the reinforcement.
5.4.1 Confirmation is required that the correct concrete mix and quantities
have been requested for the planned pours.
5.4.4 All forms and rebar shall be adequately cleaned before concrete is
poured.
5.4.5 Ready mix concrete delivered in trucks not having operable revolution
counters shall not be permitted.
5.4.6 Concrete shall be discharged from the mixer within 90 minutes or 300
revolutions of the mixer from the time the mixing water was added.
ASTM C-94, Sec. 11.7.
5.4.9 Equipment made of aluminum alloys shall not be used for pump lines,
chutes used to discharge concrete from a truck mixer.
5.4.10 Raking shall not be used for movement of concrete after placement.
5.4.11 Placing concrete by dropping from a height greater than one meter is
not acceptable, unless it will be deposited by chutes or other approved
methods." (By any means or methods that concrete is not permitted to
be dropped freely more than 1meter).
5.4.23 If the concrete placement is stopped for longer than the initial setting
time, the joint should be treated as a construction joint. Construction
joints not shown on approved for construction drawings shall only be
placed with prior approval of the client.
Cleaning by wire brushing can be done when the concrete is still soft
enough that laitance can be removed, but hard enough to prevent
aggregate from loosening. If only a few hours elapsed between
successive placement a visual check shall be carried out to ensure
that no loose particles, dirt, and laitance remain.
Concrete that has been placed recently does not require additional
water but concrete that has dried out may require saturation for a day
or more. The surface should be just damp at the time of placement.
A) Standing water shall be removed from place of deposit before concrete is
placed unless a tremie is to be used or unless otherwise permitted by both
the licensed design professional and the building official. – ACI318 Para.
26.5.2.1b
B) Masonry filler units that will be in contact with concrete shall be
prewetted prior to placing concrete. – ACI 318 Para. 26.5.2.1c
C) Concrete shall be supplied without interruptions sufficient to permit loss
of workability between successive placements that would result in cold joints.
–ACI 318 Para. 26.5.2f4
5.5.1 Forms and shoring may be removed when the concrete has already
attained its strength to support its own weight and imposed construction
loads.
5.5.2 Forms for columns, walls, side beams and other parts not supporting
the weight of concrete shall be removed as soon as the concrete has
sufficiently hardened to prevent damage to the concrete surface during
stripping operation. A 48 hours curing period would be sufficient after
casting except with forms that provide structural support. Where
expeditious removal is necessary the civil supervisor shall plan and
direct the staged removal.
5.5.3 Forms for beam soffits supporting slabs or other parts that support the
weight of the concrete shall not be removed until concrete has attained
its designed strength. Re-shoring will be provided when necessary to
safely support the structure after stripping the forms. No superimposed
load shall be applied to self-supporting members before the 28-days
strength has been verified by field-cured cylinders.
5.5.4 Form and shoring materials shall be cleaned and stockpiled promptly
after stripping. Re-use of forms that do not show any defects, is
acceptable.
5.6.2 As soon as concrete has taken its initial set (or in any case not more
than 12 hours after completion of casting) protective plastic cover
sheeting shall be removed and curing shall proceed in the following
manner.
5.6.3 For concrete other than high early strength, maintain in moist condition
generally for a period of at least 7 days following placement of
concrete.
5.6.4 Curing water shall be cool and dissolved solids shall not exceed the
specification limits.
5.7.2.3 Routing and sealing is also used to treat both fine pattern
cracks and larger, isolated cracks for waterproofing by
sealing cracks on the concrete surface where water stands,
or where hydrostatic pressure is applied.
5.7.2.4 Follow the course of crack and mark out the location for
epoxy injection nipples.
5.7.2.5 Pre-drill holes below the apex. of the V-grooved section and:
glue the nipples with epoxy or cement based mortar. A
vacuum chuck and bit, or a water-cooled core bit, is useful in
preventing the cracks from being plugged with drilling dust.
5.7.2.8 For horizontal cracks, the injection should proceed from one
end of the crack to the other in the same manner.
5.7.2.1 After the injected epoxy has cured, the surface seal should
be removed by grinding or other means as appropriate.
5.8.3 The yard supervisor will assign tasks to the appropriate section and
ensure that there is sufficient manpower available to perform the works
in a timely manner.
5.8.4 When sufficient forms have been prepared to perform a batch concrete
pour, a time shall be scheduled. Notification for the inspection of
formwork, reinforcement, anchor bolts and embedded items shall be
issued prior concrete pouring (SAIC-Q-1021 & SAIC-Q-1023).
5.8.7 Cured pre-cast elements, after attaining the specified design strength
shall be inspected and moved to the designated storage areas where
they shall be protected from any mechanical injury.
5.9.1 In situ casting shall be used for preparation of large foundations or for
foundations where safe access cannot be achieved with pre-cast units.
5.9.3 Prior to construction of the formwork, the blinding concrete pad or other
prepared area, shall be cleaned of all loose or foreign materials using
blower or hand broom. Casting, which is to be placed direct to ground
and where blinding concrete is not shown on the drawings, will require
the placement of a layer of polyethylene sheeting under reinforcement.
(SAIC-Q-1012 & SAIC-Q-1013).
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GAS Arabian
Concrete Work Services Co. Ltd
Dammam
5.9.4 Formwork shall be set around reinforcement, ensuring spacers and tie
rods to maintain position during pouring operation.
5.9.6 The blinding concrete surface shall be clean & wetted with water prior
to concrete placement, to prevent absorption of water from the
concrete.
5.9.7 Pre-inspection notification and pouring time shall be given to the client
and third party laboratory (SAIC-Q-1060). Order concrete and pump.
5.9.8
Placing Concrete
Concrete shall be placed in accordance with ACI 301 - 05,
Chapter 8, ACI 304R and this standard.
For Hot Weather Concreting requirements, When hot
weather conditions exist, contractor shall place concrete in
compliance with ACI 305R and ACI 301 - 05.
Equipment made of aluminum alloys shall not be used for
pump lines, tremies, or chutes used to discharge concrete
from a truck mixer.
Concrete shall not be placed prior to a recorded pre-
placement inspection and authorization to proceed by Saudi
Aramco.
Raking shall not be used for movement of concrete after
placement.
Vibrators shall not be used to move concrete inside forms.
Retempering of concrete after placement is prohibited.
Concrete shall not be dropped freely where reinforcing will
cause segregation nor shall it be dropped freely more than 1
m.
Concrete shall be deposited as near as possible in its final
position to avoid segregation due to re-handling or flowing.
Placed concrete shall be consolidated by mechanical
vibrating equipment supplemented by hand spading, rodding
or tamping. Equipment and procedure for consolidation of
concrete shall be in accordance with ACI 309R.
5.10 Grouting
5.10.2 Base plates and concrete surfaces must be free from oil, grease and
other deleterious materials.
5.10.5 A leak proof formwork shall be constructed using foam rubber strip or
mastic sealant beneath the constructed formwork and between joints.
Include outlets for the pre-soaking water.
5.10.9 The grout shall be cut back at a 45˚ to the lower edge of the base
plate after it has reached its initial set unless otherwise specified.
5.10.10 After completion of grouting all exposed areas shall be cured with
water for at least 7 days.
7.1.1 Construction and erection of formwork shall comply with the requirements
contained in IFC drawing and as per standard requirements Section 9 of SAES-Q-001
Construction of Concrete Structures.
7.1.2 Fixing of miscellaneous items, embedment’s and anchor bolts shall comply
with SAES-Q-001 Construction of Concrete Structures.
7.1.3 Wall or Column forms shall not be closed until the QC Inspector and other
Parties specified in the related ITPs have inspected the steel reinforcement and all
embedded items.
7.2.1 The field tests for slump, concrete temperature and ambient temperature tests
shall be performed by the Qualified Lab Technician on site to the specified testing
standards and the results recorded.
7.2.2 If any field test indicates that the concrete is deficient, the Field Technician shall
immediately notify the QC Inspector, who shall reject the concrete truckload in
question.
7.2.3 Appropriate tests of fresh concrete, on delivery to the placement site, shall be
performedin accordance with 09-SAMSS-97 Ready Mix Portland Cement Concrete.
7.2.3 The QC Inspector shall perform surveillance inspection to ensure proper cleaning
prior to placement i.e. tie wires, nails, bits of wood and cleaning of windblown sand is
removed.
7.2.4 All inspections shall perform as per inspection testing Plan, Notification shall be
issued to client as per contract / and standard requirement.
ACI 504R, “Guide to Joint Sealants for Concrete Structures,” shall be used to
prepare and select proper material for all installations.
Joint filler strips for expansion joints shall conform to ASTM D1751 or ASTM D1752.
Type shall be as noted on the design drawings.
Joints sealer shall conform to 09-SAMSS-075.
The contractor shall employ an independent Saudi Aramco approved testing agency
to perform field and laboratory testing which shall include compressive tests of
molded concrete cylinders, test for slump, unit weight, air content (where air-
entrainment is required) and fresh concrete temperature. All testing shall be in
accordance with 09-SAMSS-097, “Ready-Mix Portland Cement Concrete.”
Contractor shall submit 28 days concrete compressive strength test report to verify
& ensure the foundation & other structure that it meets the requirement of project
specification as per SAES-Q-001