ITP

PT.
KARINDA DAYA PERKASA
BATARA COMPLEX DEVELOPMENT

PROJECT
BATCHING PLANT QUALITY PLAN AND

INSPECTION AND TEST PLAN
DOC No. KDP-BCD-QA/QC-001
Rev. Originator Reviewed by Approved by Date

Name Sign Name Sign Name Sign
0 Amrullah Handoko HS Moekti 10/07/03
Machfoed
PT. KARINDA DAYA PERKASA
BATARA COMPLEX DEVELOPMENT

PROJECT
BATCHING PLANT QUALITY PLAN AND

INSPECTION AND TEST PLAN
REVISION CONTROL SHEET

Rev. Date Revision Details
0 10 – 07 - 03 Issue For Review
BETARA COMPLEX DEVELOPMENT PROJECT
QUALITY PLAN AND INSPECTION AND TEST PLAN Page 1 of 18
TABLE OF CONTENT
1. INTRODUCTION ………………………….…………….. 2
2. SCOPE …………………………………………………… 2
3. QUALITY ASSURANCE ……………………………… 2
4. QUALITY CONTROL …………………………………… 9
5. INSPECTION AND TEST ……………………………… 17
Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

1. INTRODUCTION
This Quality Plan and Inspection and Test Plan is prepared to assure the safe
operational and to provide the guidance controlling Quality, Inspection and
Test activities of ready mix concrete supply, including its raw material for
Betara Complex development Project.
2. SCOPE
The scope of this plan is:

 To assure that all related to the batch plant operational is well
prepared such as personnel assignment and mobilization, material
and equipment mobilization, establishment at jobsite, etc
 To assure that the operational batch plant will consider the safety,
health and Environmental aspect in highest priority
 To prepare the control of quality for fresh concrete and its raw
materials, including the documentation
 To prepare the test, inspection and reporting
 To assure that overall operational of batch plant will smooth running as
per project specification, code / standard, within schedule and quality.
3. QUALITY ASSURANCE OF CONCRETE SUPPLY
3.1. PERSONAL AND RECORD SYSTEM
In order to ensure the success in completion of the contract, PT.

KDP Batching Plant operation and concrete production will be under
the supervision of experienced concrete and material engineer.
PT. KDP also provide experienced and well trained concrete
technicians as well as truck mixer operators and maintenance

mechanics for trouble shooting and overhaul of the equipment in

order to guarantee the smooth running of concrete production.
All the record systems on material, quality control, maintenance,

concrete production and delivery to be arranged in efficient manner
and easily traceable when required at all time.
3.2. CONCRETE DEMAND SCHEDULE
To assure the concrete supply at the required quantity, quality and

timeframe, PT. Karinda Daya Perkasa (PT. KDP) will request PT.
Chiyoda International Indonesia (PT. CII) for appropriate arrangement
of details of concrete pouring demand schedules and detailed time
frame for concrete production. This demand schedule is required to
keep the balance of concrete demand against concrete raw material
inventory.
 Three Monthly Demand Schedule

Concrete demand schedule/ construction period which will show
monthly concrete requirement for next three month, estimate date
and start of production, type class of concrete required each month,
the date of peak demand concrete requirement, layout of pouring
location and other necessary information should be provided by PT.
CII to PT. KDP in order to allow time to arrange material delivery
schedules and other required equipment.

 Weekly Demand Schedule

Should be provided by PT. CII to PT. KDP to show quantity and class
of required concrete each day in a week. Concrete demand more
than 100 M3 in one day shall be conformed 1 (one) week before.
 Daily Demand Schedule

The confirmation of concrete production each day should be given to
PT. KDP Batching plant office at least one day (24 hours) before the
start of the production and PT. KDP will provide specials order form
for placing order to indicate the following:
 Order form number

 Name of contractor/ client
 Job site/ pouring location
 Date/ time of start of delivery
 Speed of delivery/ internal between trucks
 Total quantity of required order
 Class of concrete & type of cement
 Maximum aggregate size
 Specified slump/ workability
 Type of specified admixture and amount
 Required tests and other necessary information as required

3.2. PRODUCTION ASSURANCE
A. Raw Materials for Concrete Production and Storage

Raw materials used for the concrete shall meet the
specification requirements and be subjected to PT. CII/
PT. PetroChina International Jabung Ltd (PT. PCI Jabung
Ltd) approval. Prior to contract agreement with supplier, KDP
will invite PT. CII to visit the quarry. All aspect such as
material quality, quarry productivity, manpower / equipment
support. Etc, will be inspected and analyzed.
Cement
The cement used in concrete production shall meet the
specified requirements (what ever specified), of ASTM C 150
for type I.
All cement is stored in the cement Warehouse, protected from
water and other weather condition, while at the time of
concrete production. Cement will be transferred to the storage
bin at batch plant by screw conveyor prior to mixing.
Aggregate
The aggregate used for the concrete conforms with
ASTM C.33, i.e. river or crushed gravel with maximum size ¾
inch graded aggregate, sieve size 19 mm, armor stone,
compacted gravel and washed (natural) sand. Aggregate to
be placed separately in the stock pile in such way that
contamination, intermingling with adjacent material is avoided.
Cleaning of aggregates will be done periodically, preferably

during nighttime or no concrete production to have enough

time for water to drain.
Water
The water used for the concrete is supplied from PT. CII/ PT.
PCI Jabung Ltd designated desalination plant and stored
inside the water tank available at batch plant. The water shall
meet the specified requirements of ASTM C.94.
Admixture
Retarder will be added at the batch plant and mixed with
water during batching process to allow longer setting time.
Super plasticiser will be added at site as required to allow for
better slump / workability retention.
B. Plant and Equipment

The typical batch plant to be provided by PT. KDP is an
automatic wet process batching plant assuring that high
consistent quality and uniform concrete materials including
water are mixed with paddle pan type mixer before being
discharged in to the truck.
The function of truck mixer is as an agitator to transport

concrete, which has been mixed at the batch plant.
To supply concrete continuously without any shutdown of the

batching plant, PT. KDP will mobilize one (1) batching plant
Shin Shaeng with capacity forty five (45) Cu.m / hr as back up

supply in case of the shutdown.
C. Measurement of Materials and Records

All raw materials used for the concrete i.e. cement aggregates
and water will be measured by weight with admixture to be
measured by volume using dispenser or container/ graduated
cylinder at known volume.
Accuracy of Scale
The scale divisions used to measure the raw materials are
divided into the following:
Range of Scale Division Accuracy

Cement 600 kg 1 kg + 0.2 %
Aggregate 2.500 kg 5 kg + 0.2 %
Water 250 kg 1 kg + 0.4 %
When the amount of batched is less than the capacity of truck

being loaded, PT. KDP will provide a special form to record
each quantity of materials used in each mix at the time of
batching, indicating:
Contractor, pour location, truck number, time of batching, time
of loading, class of concrete, maximum aggregate size and
weight of each material batched.

D. Documentation/ Delivery Ticket

Before discharging the concrete at the point of delivery, PT.
KDP will provide a delivery ticket for each batch of concrete
detailing the following information:
 Name of contractor
 Job site/ pouring location
 Date of delivery
 Mix/ class of concrete
 Cement type
 Maximum aggregate size
 Specified slump
 Volume/ quantity in one cubic meter
 Time of batching
 Time of arrival at site
 Remarks (if any excess or surplus requested RMC supply
shall be mentioned for what and where, and any other
necessary information)
 Start unloading
 Finish unloading
 Time return to plant
 Other necessary information
After the completion of discharge the above delivery ticket

should be countersigned by user, approved by PT. CII
authorized officer and returned to PT. KDP Batch Plant.
E. SHE Program
PT. KDP will fully aware with SHE program during the
operational of batch plant. All employees will be protected with
standard PPE as per Contractor SHE procedure.
Dust controlling program will be implemented in batch plant
area and all jobsite area with other Subcontractor with PT. CII
as coordinator. The employees will be equipped with proper
masker and safety glasses. Regular safety talk will be
conducted as per Contractor SHE program to assure that all
employees will always aware to them self and others from
Unsafe condition.
IV. QUALITY CONTROL
IV.1. MATERIAL CONTROL
Cement
The physical and chemical analysis of cement used for the
concrete will be evaluated based on cement mill certificate
provided by manufacturer or supplier and subject to the
approval of PT. KDP

Aggregate
Routine test on fine and coarse aggregate for concrete
production and quality control purpose to be carried out
regularly at PT. KDP laboratory, i.e.:
 Gradation test
 Moisture content
 Material finer than sieve no. 200
 Specific gravity
 Bulk density
 Water absorption
On the arrival of new material and before it is unloaded to

stock pile all the aggregate will be tested at PT. KDP
laboratory in accordance with relevant specification.
Specification
The complete test on chemical and physical properties of
aggregate for the approval of material used for the concrete
will be done by the approved independent testing laboratory
and comprise:
 Gradation
 Water absorption
 Specific gravity
 Material finer than sieve no. 200

 Flakiness index
 Soundness test
 Chloride content (Cl)
 Sulphate content (SO3)
 Alkali reactivity in aggregate
Water
Since the water used for the concrete is supplied from PT. CII/
PT. PCI Jabung Ltd main desalination plant, i.e. portable
water, the test on water will be done only for approval
purpose, i.e. on:
 PH value
 Total dissolved solid (TDS)
 Chloride content (Cl)
 Sulphate content (SO3)
 Suspended soil
 Alkali carbonate
Admixture
The quality of admixture will be checked regularly based on
the specific gravity of the liquid.
IV.2. EQUIPMENT CONTROL

All plant and equipment will be maintained in a clean and
efficient working condition. All knife edges on weighing

equipment will be kept clean all times. All hoppers and doors
will be kept clean and in efficient working order. Any build-up
in the hopper will be cleaned out daily.
The mixer at Batch Plant as well as the truck mixer will not be
loaded in excess of manufacture’s rated capacity.
Central and truck mixers will be maintained in efficient and
clean condition with no appreciable build-up of hardened
concrete in the mixing drum, on blades or in the loading
hopper for discharge chutes. Regular check and repairs (if
necessary) will be done on mixing blades.
Calibration of Weighing Equipment

Calibration of all scales used for cement, aggregate, water
and admixture dispenser will be done before the start of
concrete production subject to the approval of PT. CII / PT.
PCI Jabung Ltd.
IV.3. PRODUCTION CONTROL
At the start of batching, the central mixer and the truck mixer
will be cleaned from any retained water inside the drum used
for washing out purposes.
All the concrete will be batched based on the batch card

provided by PT. KDP Technical Department using the mix
proportions, which have been approved by PT. KDP at initial

trial mixes.
All the material will be measured within defined limits of the

above batch card and any necessary adjustment will be made
to allow for variation of the moisture in aggregate to be done
by PT. KDP laboratory officer based on the approved tables.
Control of Water Content, Workability and Fresh Concrete

During mixing the amount of water introduced into the mixer
will be strictly controlled and no additional water other than
specified will be added to the truck mixer before the delivery,
unless specifically required and signed by PT. CII / PT. PCI
Jabung Ltd.
After the completion of batching, the mixed concrete in the

truck mixer will be inspected visually before delivery.
Sampling and testing of concrete for workability will be carried

out in accordance with ASTM C-143 and performed at the
interval as per specification BCD03-01-00-45-SPC-002-1 Rev.
0 “Specification Concrete Structure”
The minimum of cylinder specimen for samples shall be 6

(six) for each day’s operation or each 50 m3 of concrete
production. Field test will be carried out regularly to detect the
variation of concrete density and other properties of materials.
Cylinder specimens will be made in accordance with ASTM C-

39. All cylinders shall be marked at the time of casting with
the date, class of concrete and other necessary information to
identify the part of the work and from where such cylinders
were taken and the record will be made available for further
inspection.
Hot Weather Control

Generally, if concrete strengths are satisfactory and curing
practices are sufficient to avoid undesirable drying of
surfaces, durability of hot weather concrete should not be
greatly different from similar concrete place at normal
temperature, a summing the presence of a desirable air-void
system if it is going to be exposed to cycles of freezing and
thawing.
However, the following steps will be taken in order to avoid

the about problems, such as hydration at higher temperature
(concrete temperature) and evaporation rate of moisture from
the freshly mixed concrete in hot weather:
 Concrete and water will be stored in a shaded area to

reduce the temperature increase due to direct sunshine.
 Fine and coarse aggregate will be sprayed with water as
required in order to further reduce the aggregate’s
temperature. (Moisture cement of aggregate must be
taken into account for proper water to content ration (W/C)
 As initial concrete temperature will affect the strength, the

temperature of the mixing water has the greatest effect to
the concrete strength. The temperature of the mixing water
is the easiest thing to control even though the mixing water
is the smallest portion compared to the other ingredients.
The use of cold mixing water will be utilized by providing “
Water Chiller” which can decrease the water temperature
up to 12 C degree.
 Concrete admixtures, such as sika plastiment RTD 01
retarder will be used as required in order to offset the
negative effect of high mixing temperature.
 The dispatching of mixed concrete by trucks will be
coordinated to avoid delays in delivery i.e. minimized
delivery times for concrete placement. The elapsed time of
batching to placement of concrete mixed will result in
significant increases in mixing water demand or in slump
loose.
Stripping time, Marking and Curing of cylinder

Specimens.
The cylinder specimens were made during concrete
production will be stripped out from the mould at minimum 20
hours and not more than 48 hours after the casting.
All the cylinder specimens will be identified with waterproof

pen maker in accordance to laboratory code number date of
casting and other necessary information. The record showing

class concrete, pouring location dates of cast etc. Will be
available for further inspection.
After the completion of the above process all cylinder

specimens will be cured inside a wear take in accordance with
ASTM C-192 and tested at designated ages.
V. INSPECTION AND TEST
V.1. CONCRETE RAW MATERIAL TEST
Prior to contract agreement with concrete raw material

supplier, KDP will invite PT. CII / PT PCI to have joint
inspection and test at sand and aggregate quarry. The
sample will be taken and tested in accordance with ASTM
standard.
Prior to unloading from the barge, PT. KDP will inform to PT.
CII / PT. PCI to inspect and test the aggregate and sand. The
visual check and gradation test shall be done soon. PT. KDP
will inform the estimated arrival date each shipment and issue
‘application for inspection’.
Contractor will also regularly issue to PT. CII / PT. PCI ‘the
manufacture certificate’ of cement.

V.2. CONCRETE SLUMP TEST
Concrete slump test will be taken daily with the following

basis:
 From the first batch mixed
 From the batch mixed where the cylinder specimen is
taken
 Each class of concrete for every 50 m3
 As requested by PT. CII / PT. PCI
V.3. CONCRETE TEMPERATURE TEST
Concrete temperature test will be taken on daily basis,

especially during DAY TIME or Hot Weather condition.
V.4. CONCRETE COMPRESSIVE STRENGTH TEST
Concrete cylinder strength test will be taken daily basis at the

3, 7 days and 28 days age of concrete. Evaluation of
compressive strength test will be done using the approved
method (ACI 214. ACI 318 and other relevant standards).
Compressive strength charts to monitor the change in target

mean (average) strength, standard deviation will be drawn on
a control chart that will kept available for inspection.

Statistical evaluation of cylinder compressive strength test to

measure the actual average strength, standard deviation and
coefficient of variation for each class of concrete to be done
after sufficient quantity of 28 days compressive strength of
each class of concrete are available.
V.5. BATCHING PLANT CALIBRATION
Prior to trial mix, the calibration of batching plant will be

conducted by government authority, inspected by PT. CII / PT.
PCI.
The internal calibration will be conducted regularly on three
monthly basis.

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PT.

KARINDA DAYA PERKASA

BATARA COMPLEX DEVELOPMENT

BATCHING PLANT QUALITY PLAN AND

DOC No. KDP-BCD-QA/QC-001

Rev. Originator Reviewed by Approved by Date

BATARA COMPLEX DEVELOPMENT

BATCHING PLANT QUALITY PLAN AND

REVISION CONTROL SHEET

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 1 of 18

3. QUALITY ASSURANCE ……………………………… 2

4. QUALITY CONTROL …………………………………… 9

5. INSPECTION AND TEST ……………………………… 17

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 2 of 18

The scope of this plan is:

3. QUALITY ASSURANCE OF CONCRETE SUPPLY

3.1. PERSONAL AND RECORD SYSTEM

In order to ensure the success in completion of the contract, PT.

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 3 of 18

mechanics for trouble shooting and overhaul of the equipment in

All the record systems on material, quality control, maintenance,

3.2. CONCRETE DEMAND SCHEDULE

To assure the concrete supply at the required quantity, quality and

 Three Monthly Demand Schedule

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 4 of 18

 Weekly Demand Schedule

 Daily Demand Schedule

 Order form number

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 5 of 18

3.2. PRODUCTION ASSURANCE

A. Raw Materials for Concrete Production and Storage

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 6 of 18

during nighttime or no concrete production to have enough

B. Plant and Equipment

The function of truck mixer is as an agitator to transport

To supply concrete continuously without any shutdown of the

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 7 of 18

Shin Shaeng with capacity forty five (45) Cu.m / hr as back up

C. Measurement of Materials and Records

Range of Scale Division Accuracy

When the amount of batched is less than the capacity of truck

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 8 of 18

D. Documentation/ Delivery Ticket

After the completion of discharge the above delivery ticket

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 9 of 18

IV. QUALITY CONTROL

IV.1. MATERIAL CONTROL

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 10 of 18

On the arrival of new material and before it is unloaded to

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 11 of 18

IV.2. EQUIPMENT CONTROL

Originator : PT. KARINDA DAYA PERKASA Revision No. : 0

QUALITY PLAN AND INSPECTION AND TEST PLAN Page 12 of 18

Calibration of Weighing Equipment