PR808-01 Civil Works

Nigeria LNG Limited Civil works
Natural Gas Liquefaction Complex Revision B2

Bonny Island, Nigeria Page 1 of 13
NLNG PLUS PROJECT
T S
K J
CONSTRUCTION
PROJECT PROCEDURE No. PR 808-01
QUALITY CONTROL DOCUMENTATION

CIVIL WORKS
Rev B1 Rev B2 Rev B3 Rev B4

Prepared By:
A Chopra
Checked By:
D Gevaux D Gevaux
Approved By:
(Executive Project Manager)
JP Oppenheim JP Oppenheim
Date:
Pages Revised: 4,8,9,11,12,13
& forms
NOTE: Type in date, and initials and sign the appropriate box for the current revision.
JP 1000 NLG
Procedure PR 808-01
/conversion/tmp/scratch/489886083.doc
TABLE OF CONTENTS
1.0 OBJECTIVE
2.0 QUALITY CONTROL PROCEDURES
3.0 INSPECTION AND TEST PLANS
4.0 RESPONSIBILITIES
5.0 IMPLEMENTATION
5.1 Reinforcement steel
5.2 Anchor Bolts
5.3 Water
5.4 Cement
5.5 Admixtures
5.6 Aggregates
5.7 Other Civil Materials
5.9 Concrete Placement
5.10 Fill Placement and Compaction
5.11 Foundation Settlement
5.12 Asphalt Surfacing
5.13 Concrete Products (Pre-Cast Units)
5.14 Quality Control Testing Performed by Subcontractor
5.15 Surveying
6.0 RECORDS
7.0 REFERENCES
8.0 QUALITY CONTROL FORMS
JP 1000 NLG
Procedure PR 808-01
1.0 OBJECTIVE
The purpose of this procedure is to outline the project quality requirements
pertaining to Civil Works and to provide documents for use by the
Subcontractor, Contractor and Company to record necessary data to ensure
correct materials, installation, workmanship, inspection and testing was
accomplished, witnessed and approved as required by project specifications.
2.0 QUALITY CONTROL PROCEDURES

Quality control procedures covering the subcontractor's scope of work shall be
submitted to the Contractor QA/QC Manager for review within 60 days after
award of subcontract. The procedures will identify the persons responsible for
performing the work, conducting quality control inspections, preparing, signing
and maintaining quality documentation, interfacing with Contractor QA/QC
group and other functions required to assure complete implementation of a
quality program that is acceptable to the Contractor and the Company. The
procedures will be reviewed/commented and must be approved prior to the start
of construction.
The Subcontractor quality control procedures shall contain all of the elements
needed for the craftsmen, supervisors and inspectors to understand what is to
be done by each party, when and how it is to be accomplished, the necessary
materials, equipment and documents required, and how it shall be controlled
and recorded.
3.0 INSPECTION AND TEST PLANS

The subcontractor shall prepare inspection and test plans in accordance with
project procedure PR 831 to list each stage of construction/inspection with
references to the applicable code, standard, drawing and specification. These
inspection and test plans must be approved by the Contractor no later than 30
days before scheduled construction. The subcontractor shall submit a request
for Contractor Hold and Witness inspection items no later than one working day
before the inspection is to take place.
It is the Subcontractors' responsibility to include the applicable QC procedure,
Standard, Specification and inspection form numbers for each construction
activity on the Inspection and Test Plans.
4.0 RESPONSIBILITIES
The subcontractor is responsible for implementing a quality assurance/quality
control program, which includes 100% inspection and documentation of the
work. The Contractor area engineers and supervisors will provide assistance to
the subcontractors as needed and will provide full time surveillance of the work
in progress. The engineers will attend the Hold, Witness and Random
inspection and the Records Review as shown on the subcontractors' inspection
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Procedure PR 808-01
and test plan.
The Contractor QA personnel will audit and monitor the quality
control/inspection of the work. The QC and NDE personnel will conduct
inspections of welding and civil operations and will perform the non-destructive
examinations required by project specifications. Contractor QA/QC will
determine if the inspections are being performed in a competent and
satisfactory manner and that the relevant documentation is being prepared,
signed and maintained in a retrievable manner.
5.0 IMPLEMENTATION
5.1 Reinforcement steel

Subcontractor shall submit (where required) material certificates for all
reinforcing steel procured by subcontractor for Contractor’s review prior to issue
for use. Locally procured / manufactured reinforcement steel shall require
additional testing as per the Project Specification Amendment. Bundles shall
be tagged with identifying marks that can be matched to the material
certificates. Identification shall be maintained during storage and until
fabrication and installation is started.
Subcontractor shall retain records verifying that bending and fabrication
dimension tolerances were maintained. Reinforcement will be inspected
immediately prior to concrete placement by Subcontractor and Contractor.
5.2 Anchor Bolts

Subcontractor shall obtain material certificates for all Subcontractor-supplied
anchor bolt assemblies. Subcontractor is responsible for assuring installation of
the correct size, type and length of anchor bolt within acceptable tolerances
prior to inspection by Contractor.
5.3 Water
Subcontractor shall perform water analyses via an Independent Test Laboratory
as per the applicable British Standard at the frequency specified in the Project
Specification Amendment. Results shall be reported on Form PR 808-01-A18
or as per the Independent Test Laboratory Format. Subcontractor QC shall
confirm on a daily basis that only water from approved sources is used in the
concrete and grout mixes. Additional tests on water shall be conducted by the
Subcontractor as per the Project Specification Amendment, where required.
5.4 Cement
Cement shall be tested to prove compliance with applicable Standards as
required in the Project Specification and Amendment. Subcontractor shall retain
MTRs of each delivery of cement to the batch plant to confirm that all cement
has been tested and meets these requirements. Cement shall not be received
without the proper test certificate.
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Procedure PR 808-01
For cement older than three (3) months, Subcontractor shall conduct the
required tests specified in the Project Specification Amendment and shall
prepare Form PR 808-01-A17 , PR 808-01-A17.1 or Independent Test
Laboratory for Contractor approval.
5.5 Admixtures
Use of admixtures in concrete shall be subject to Contractor approvals.
Admixtures shall meet the requirements of the Project Specification and the
referenced ASTM standard.
Subcontractors supplying ready-mix concrete shall retain manufacturer and
laboratory certificates of all admixtures approved to verify that admixtures
supplied for use in the concrete is the same as those subjected to the required
testing.
5.6 Aggregates
All aggregates shall be tested and approved prior to use in a concrete mix.
Subcontractor shall be responsible for daily inspection and periodic testing of
materials during receipt and stockpiling operation.
Subcontractors supplying ready-mixed concrete shall issue test certifications to
Contractor to verify that aggregates to be used in concrete comply with Project
Specifications.
The following forms may be used to document test results. This is not an all
inclusive list of tests that will be required on concrete materials. Tests
performed by offsite Independent Test Laboratories (ITL) may be submitted on
ITL forms.
Note: Combined aggregates grading is not recommended for use for concrete
grades C20 or higher.
PR 808-01-A9 : Sieve Analysis of combined aggregates
(including organic impurities )
PR 808-01-A15 : Sieve Analysis of Aggregates
PR 808-01-A20-01 : 10% Fines Value
PR 808-01-A26 : Material <75 Microns
PR 808-01-A39 : Chemical Analysis of Aggregates
PR 808-01-A44 : Clay Lumps Test
PR 808-01-A45 : Soundness test
5.7 Other Civil Materials

Subcontractors are responsible to select the appropriate materials, and comply
with project specifications and / or drawings. Form PR 808-01-A49, shall be
used for all Civil Materials not mentioned here for approval.
JP 1000 NLG
Procedure PR 808-01
5.8 Concrete Mixes
After receiving approval from the Contractor of (1) source of materials (2) the
ingredients to be used, and (3) proposed mix quantities, Subcontractor shall
prepare and test trial mixes. The trial mixes shall be in accordance with DEP
34.19.20.31,APPENDIX 2. A guideline for a mix design report and durability
RILEM test method are reported on forms PR-808-01-A46 and A21.The
potential for alkali-aggregate reactivity (ASTM C 289) and coal/lignite content
( ASTM C123 ) shall be investigated by the third party laboratory for initial
approval and anytime there is a changing of source of the aggregates. Results
of the trial mixes must be submitted to Contractor for approval not less than 30
days prior to the scheduled start of concrete construction.
Each of these steps shall be included on Subcontractor inspection and test plan
and will be witnessed by Contractor. Each design mix must be approved by
Contractor prior to use in permanent plant constructions.
5.8.1 Batch Plant

After erection of the batch plant at site and prior to production of concrete for
permanent constructions, subcontractor shall conduct the tests and calibrations
required by the specifications, British Standards and industry practice. These
tests and calibrations will be witnessed by the Contractor and shall be
documented, the document to be used for these purposes is PR808-01-A51
plus appropriate Reports generated during inspection.
5.9 Concrete Placement

All forms used in these procedures shall be retained on file available at all times
for Contractors to see and if necessary to copy. Each type of form shall have a
sequential, discrete number of its own.
No concrete for any structural or foundation requirement shall be placed without
application of this procedure.
Subcontractor shall prepare a Concrete Pre-placement Checklist, Form PR-
808-01- A1 and obtain Contractor’s signature prior to placing concrete. Where
parts of any foundation or structure are poured separately, a separate Pre-
placement form is required. Subcontractor shall give 24-hours written notice to
Contractor of foundation/item number, time and location for the concrete
intended to be placed.
Subcontractor shall issue to the batch plant a Mix Order, Form PR 808-01-A27,
including the sequential number of the Pre-placement form as well as its own
sequential Mix Order number. Contractor’s approval signature is required on
this form to ensure that the Pre-placement checklist has been duly completed
and approved before concrete is ordered and to ensure the correct concrete is
requested.
The Batch Plant shall use the Mix Order form, PR 808-01- A27 to record the
batch information of the mix and retain this record on file. Delivery Notes shall
not be issued until the Site Contractor QC representative at the batch plant has
JP 1000 NLG
Procedure PR 808-01
signed the Mix Order forms after mixing is complete.
When ready to deliver a mix the batch plant shall issue a Delivery Note, form
PR 808-01- A16, also indicating the sequential number of the relevant Mix
Order as well as its own. This shall be transported with the driver to the point of
placement. The concrete foreman will sign the note and the driver will return it
to the batch plant for filling.
Subcontractor shall issue a Concrete docket, detailing information about the
placement, Form PR 808-01-A27. This shall indicate both Mix Order and
Delivery Note numbers in addition to its own. Each separate concrete pour
shall have its own Concrete Docket (so it is possible that a given delivery will
cover more than one pour). When a pour requires more than one delivery a
separate page of the Concrete Docket shall be used and numbered as ‘sheet x
of y’ in the series for the particular pour. Any forms used to record sample
taken for fresh concrete tests shall also indicate the relevant Concrete Docket
number. Subcontractor shall attach the Concrete Dockets to the matching Pre-
placement forms on his files.
Suppliers of ready-mixed concrete shall allocate a sequential batch number to
all batches of concrete supplied and clearly indicate on the delivery docket the
applicable reference number. In the case of Subcontractor-supplied ready-
mixed concrete, docket number should be prefixed with the Subcontract
identifier (number).
Supplier of ready-mixed concrete shall maintain copies of details of mix
proportions of concrete batches dispatched.
Batch plant detail shall as a minimum display the time, date, mix components,
batch number and quantity of each batch, as well as subcontract number to
which the concrete was delivered.
Subcontractor shall document each fresh concrete test results on the following
forms:
PR 808-01-A19 : Chemical Analysis of fresh Concrete

PR 808-01-A23 : Temperature of all Constituents of a mix
PR 808-01-A24 : Fresh Concrete Testing in the Laboratory
PR 808-01-A25 : Determination of moisture Content
PR 808-01-A43 : Particle density and water absorption
Subcontractors shall document each hardened concrete test result using the
forms PR808-01-A10, A22, A29. Relationship between the rebound values and
compression test of cubes shall be maintained. The results of each test are to
be submitted to Contractor’s QA/QC Manager after completion of seven (7) and
twenty-eight (28) day tests for each set of cubes. Failure of any sample to meet
the specified strength shall be reported immediately to the QA/QC Manager,
who will notify the Site Technical Manager for resolution. Non-conforming test
results shall be documented per Procedure PR 809, Non-Conformance
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Procedure PR 808-01
Reports.
5.10 Fill Placement and Compaction

Subcontractor shall place and compact fill material in accordance with Project
Specifications.
Subcontractor shall implement an Excavation Log Book recording the following
as a minimum :
a) depth, area and volume of each excavation
b) ground water-level encountered
c) date of excavation
d) date and results of inspection of the bearing layer
e) date of pouring blinding layer of concrete
f) date of pouring foundation.
g) date protective coating applied to concrete
h) date of filling/back filling
i) number of fill layers,
j) compaction method
k) results of compaction tests
Prior to backfilling, Subcontractor shall complete Inspection Report for Post-

Concreting / Pre-Backfilling (Form PR 808-01-A3), verifying that all preparatory
work has been completed and accepted.
When Subcontractor is satisfied that the required compaction in an area has
been achieved, he shall complete Placement and Compaction of Fill Materials
Record(Form PR 808-01-A4) and submit to Contractor’s Inspector for signature.
Testing results are to be attached to this as backup of testing acceptability.
Form PR 808-01-A4 shall then be forwarded to Contractor’s QA/QC Manager
along with copies of test reports attached for acceptance by Contractor.
Prior to backfilling of underground services, i.e. piping and cables, an
Authorisation to Backfill (Cables or Pipe Installations) (Form PR 808-01-A5)
shall be prepared by Subcontractor and Contractor’s acceptance signatures
obtained. Prior to QC Inspector signature it is required to obtain the craft
Supervisor’s approval signature (i.e. piping or electrical/instrument).
Subcontractor shall test soil for filling/backfilling for suitability prior and after
compaction (Forms PR 808-01-A36,37,38,40, 41or 42 ,47 or 60, 50 ,52).
5.11 Foundation Settlement

Areas of the site to be preloaded will be monitored using settlement markers
installed in the pre-load material and instrumentation installed in the ground
below the pre-load mounds. On completion of pre-loading and commencement
of foundation construction, settlement marker pins shall be installed in the top
surface of foundations and Contractor will monitor settlement up to
commissioning of the plant, recording results on a regular basis.
JP 1000 NLG
Procedure PR 808-01
Contractor’s Site Technical Manager shall be responsible for designating which
foundations shall be checked for settlement. It is anticipated that this shall
include major foundations and any suspect areas.
Contractor’s nominated Surveyor shall be responsible for implementing
settlement readings on the designated foundations and recording all readings
on Foundation Settlement Form (Form PR 808-01-A6).
5.12 Asphalt Surfacing

Excavation and fill shall be per Project Drawings and Specifications.
Subcontractor shall obtain Contractor approval for the installation of subbase
and base course prior to the application of primer and laying of asphaltic
concrete. Subcontractor shall issue to Contractor certificates and charts relating
to mechanical sprayers.
Subcontractor shall obtain Contractor’s approval of the surface course
materials before using same to ensure that material meets the requirements of
the Project Drawings and Specifications. Forms PR 808-1A-20 or A20-1 or A20-
2 and A28 (only for initial approval of mix); PR 808-01-A32, PR 808-01-A33
(mix approval and during the asphalt installation) PR808-01-A31,PR808-01-A48
(only during production). Subcontractor shall prepare and maintain a
Bituminous Surfacing Record (Form PR 808-01-A7).
Contractor shall witness all bituminous surface spraying and asphalt laying.
5.13 Concrete Products (Pre-Cast Units)

It shall be the responsibility of the Subcontractor to supply concrete mixes,
which comply in all respects to Project Specifications.
Trial mixes shall be implemented by the Subcontractor and the results
submitted to the Contractor for review and acceptance prior to use.
Subcontractor shall progressively compile a Process Sheet for manufacture of
Pre-Cast Units. Inspection Report for Pre-Cast Concrete (Form PR 808-01-A8)
shall be used, with each unit recorded on a separate sheet.
Subcontractor shall comply with all requirements of Section 5.9 of this
Procedure for concrete placement.
5.14 Quality Control Testing Performed by Subcontractor

Unique test number shall be allocated to all Quality Control Test as follows:
/
Subcontract No. Sequential No
Subcontractor shall maintain a log of all testing performed incorporating as a

minimum, the following:
a) test number
b) location of test (drawing number)
JP 1000 NLG
Procedure PR 808-01
c) type of test
d) test report number
e) result of test.
A master set of Civil Plot Plans with areas marked up to reflect location of all
acceptance testing performed shall be maintained by Subcontractor and
available for Contractor review.
5.15 Surveying
Subcontractor will carry out general surveying and levelling using modern and
properly calibrated equipment and by employing suitably qualified surveyor(s)
on site.
Using appropriate surveying and levelling methods, all excavation to foundation
bases, pile caps, sewer boxes, plinth blocks, walls, pipework and paving will be
checked and results recorded in the survey log (PR 808-01-A11).
For finished concrete surfaces, invert levels for pipework and paving to required
falls, surveying checks will be carried out and the surveyor will be required to
complete the standard form PR-808-01-A11 - Surveying Log. Such forms,
where required, will be provided with other relevant quality control documents
for Contractor’s verification and final submission.
The surveyor will carry out periodical calibration checks on surveying
instruments - theodolite, EDM, and level, and will maintain the records of such
calibrations by completing the forms PR-808-01-A12, PR-808-01-A13 and PR-
808-01-A14 or approved equivalent forms as per the Subcontractors Inspection,
Measuring & Testing Equipment Procedure.
The final locations and projections of anchor bolts are critical and surveying
techniques must establish these projections and locations within the tolerances
dictated by the Project Specifications.
6.0 RECORDS
The subcontractors' quality system shall provide procedures to assure that
sufficient records are maintained to verify that the requirements of the
subcontract documents have been fully met. He will obtain the required
signatures of the Contractor and will maintain all documentation required for
handover of the work.
7.0 REFERENCES
DEP 00.00.05.05-Gen. Index to DEP publications and standard specifications

DEP 34.11.00.11-Gen + T-12.416.008 Site Preparation and Earthwork
JP 1000 NLG
Procedure PR 808-01
DEP 34.13.20.31-Gen + T-12.416.009 Roads, Paving, Surfacing, Slope
Protection and Fencing
DEP 34.19.20.31-Gen + T-12.416.015 Reinforced Concrete Foundations and
Structures
Project Procedures As applicable to subcontract scope of work
8.0 QUALITY CONTROL FORMS
PR 808-01-A1 : Concrete Pre-Placement Checklist

PR 808-01-A3 : Post Pour Inspection and Concrete Repair
PR 808-01-A4 : Placement and Compaction of Fill Material Record
PR 808-01-A5 : Authorisation to Backfill (Cables or Pipe Installations)
PR 808-01-A6 : Foundation Settlement – Refer to Spec T-12.440.934
PR 808-01-A7 : Bituminous Surfacing Record
PR 808-01-A8 : Inspection Report for Pre-Cast Concrete
PR 808-01-A9 : Testing of Aggregates Sieve Analysis of combined
Aggregates
PR 808-01-A10 : Compression Tests on Concrete Cubes
PR 808-01-A10-0 1 : Grout Cube Compression Report
PR 808-01-A11 : Survey Log
PR 808-01-A12 : Surveying Instrument Check-Theodolite
PR 808-01-A13 : Surveying Instrument Check-EDM
PR 808-01-A14 : Surveying Instrument Check-Level
PR 808-01-A15 : Testing of Aggregates
PR 808-01-A16 : Concrete Delivery Note
PR 808-01-A17 : Compression Setting Time and sulphate/Test of Cement -
PR 808-01-A17-01 : Fineness & Soundness Test On Cement
PR 808-01-A18 : Test of Water Used for Concrete –
PR 808-01-A19 : Chemical Analysis of Fresh Concrete
PR 808-01-A19-01 : Determination of Chloride Content in Aggregate ( Quick
test )
PR808-01-A19-02 : Determination of Sulphate Content in Aggregate ( Quick
Test )
PR 808-01-A20 : Los Angeles Abrasion Test – ASTM C131
PR 808-01-A20-01 : 10% Fine Value – BS812 Part III
PR 808-01-A20-02 : Aggregate Impact Value
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Procedure PR 808-01
PR 808-01-A21 : Impermeability Test on Concrete Cubes
PR 808-01-A22 : Rebound Hammer Test on Concrete Cubes
PR 808-01-A23 : Temperature of All Constituents of the Mix
PR 808-01-A24 : Fresh Concrete Testing in the Laboratory
PR 808-01-A25 : Moisture Content of Aggregates
PR 808-01-A26 : Material < 75 Microns
PR 808-01-A27 Mix Order and Pour Docket Combined
PR 808-01-A28 : Flakiness and Elongation Index
PR 808-01-A29 : Concrete Statistical Analysis
PR 808-01-A29-01 : Concrete Statistical Trend
PR 808-01-A30 : Grouting for Steel Structures and Equipment
PR 808-01-A31 : Bitumen Analysis & Extraction Test
PR 808-01-A32 : Computation of Properties of Asphalt Mixtures
PR 808-01-A33 : Computation of Properties of Asphalt Mixtures
PR 808-01-A34 : Bitumen Spray Test
PR 808-01-A35 : Core Test

PR 808-01-A36 : Determination of Atterberg Limits
PR 808-01-A37 : Compaction Test – Modified Proctor Test
PR 808-01-A38 : Sieve Analysis of soil
PR 808-01-A39 : Chemical Analysis of aggregates
PR 808-01-A40 : Determination of Density (Cylinder Method)
PR 808-01-A41 : Plate Bearing Test (Pressure-Setting Curve)
PR 808-01-A42 : California Bearing Ratio (CBR – Curve)
PR 808-01-A43 : Particle Density and Water Absorption Test
PR 808-01-A44 : Clay Lumps Test
PR 808-01 A45 : Soundness Test
PR 808-01-A46 : Concrete mix design report
PR808-01- A47 : Organic matter content of soil
PR 808-01-A48 : Asphalt concrete site control
PR 808-01-A49 : Civil Material Approval Request
PR 808-01-A50 : Determination of Moister content
PR 808-01-A51 : Works Inspection Report
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Procedure PR 808-01
PR 808-01-A52 : Determination of In-situ Density ( Sand Cone Method )
PR 808-01-A53 : Determination of Compressive Strength
PR 808-01-A54 : Determination of Unconfined Compressive Strength
PR 808-01-A55 : Sand Cement Stabilisation Rate of Spread
PR 808-01-A56 : Grouting for Platipus Anchor
PR 808-01-A57 : Water Proofing Work Construction Inspection Report
PR 808-01-A58 : Masonry Works Rendering Mortar Compressive Tests
PR 808-01-A59 : Masonry Works Erection Mortar Compressive Tests
PR 808-01-A60 : Sand Equivalent Value of Soil and Fine Aggregates
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Procedure PR 808-01

PR808-01 Civil Works

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Nigeria LNG Limited Civil works

Natural Gas Liquefaction Complex Revision B2

PROJECT PROCEDURE No. PR 808-01

QUALITY CONTROL DOCUMENTATION

Rev B1 Rev B2 Rev B3 Rev B4

2.0 QUALITY CONTROL PROCEDURES

3.0 INSPECTION AND TEST PLANS

5.1 Reinforcement steel

5.2 Anchor Bolts

5.7 Other Civil Materials

5.8.1 Batch Plant

5.9 Concrete Placement

PR 808-01-A19 : Chemical Analysis of fresh Concrete

5.10 Fill Placement and Compaction

Prior to backfilling, Subcontractor shall complete Inspection Report for Post-

5.11 Foundation Settlement

5.12 Asphalt Surfacing

5.13 Concrete Products (Pre-Cast Units)

5.14 Quality Control Testing Performed by Subcontractor

Subcontractor shall maintain a log of all testing performed incorporating as a

DEP 00.00.05.05-Gen. Index to DEP publications and standard specifications

8.0 QUALITY CONTROL FORMS

PR 808-01-A1 : Concrete Pre-Placement Checklist

PR 808-01-A35 : Core Test

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