ESSO EXPLORATION &

PRODUCTION CHAD INC. CCS 4-10-1

CONCRETE DESIGN AND
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TECHNICAL SPECIFICATION Rev. 0 30 Oct 96

CHAD DEVELOPMENT PROJECT

TECHNICAL SPECIFICATION

Rev. Date No. of Prepared Reviewe Approved Revision Details

No. Pages By d By By

0 23 IFP Issue

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TECHNICAL SPECIFICATION Rev. 0 30 Oct 96

TABLE OF CONTENTS

1.0 SCOPE ......................................................................................................................................4

2.0 SUMMARY OF ADDITIONAL REQUIREMENTS...................................................................4

3.0 CONCRETE SELECTION AND MIX DESIGN CRITERIA.....................................................6

4.0 FORMWORK.............................................................................................................................9

5.0 REINFORCING STEEL............................................................................................................9

6.0 EPOXY-COATED REINFORCING STEEL...........................................................................10

7.0 ANCHOR BOLTS AND OTHER EMBEDDED ITEMS.........................................................11

8.0 DELIVERY ...............................................................................................................................13

9.0 PLACING .................................................................................................................................13

10.0 HOT WEATHER CONCRETING .........................................................................................14

11.0 EXPANSION JOINTS AND CONSTRUCTION JOINTS....................................................15

12.0 FINISHING.............................................................................................................................15

13.0 PATCHING AND REPAIR OF SURFACE DEFECTS.........................................................15

14.0 CURING.................................................................................................................................16

15.0 PAVING..................................................................................................................................16

16.0 CONCRETE STRUCTURES...............................................................................................17

17.0 LIQUID RETAINING STRUCTURES ..................................................................................17

18.0 REINFORCED CONCRETE FOUNDATIONS....................................................................20

19.0 UNDERGROUND PROTECTIVE CONCRETE .................................................................22

20.0 INSPECTION AND TESTING..............................................................................................22

21.0 EVALUATION AND ACCEPTANCE.....................................................................................22

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TECHNICAL SPECIFICATION Rev. 0 30 Oct 96

LIST OF TABLES
TABLE 1 ..........................................................................................................................................4
TABLE 2 ..........................................................................................................................................7
TABLE 3 ..........................................................................................................................................8
TABLE 4 ..........................................................................................................................................8
TABLE 5 ........................................................................................................................................20
TABLE 6 ........................................................................................................................................20

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CONCRETE DESIGN AND
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TECHNICAL SPECIFICATION Rev. 0 30 Oct 96

1.0 SCOPE
1.1 This Specification covers concrete design and construction.

1.2 An asterisk (*) indicates that additional information is required. This information is
provided in other project documents or will be furnished during the detailed
engineering phase.

1.3 A pound sign (#) indicates that ESSO review/approval is required before design
and/or construction is finalized or equipment is purchased.

2.0 SUMMARY OF ADDITIONAL REQUIREMENTS

2.1 Table 1 lists the codes, specifications, standards and publications which shall be
used with this Specification.
TABLE 1

SPECIFICATIONS
CCS
3-7-3 Thrust Blocks for Underground Cast Iron and Non-Metallic Pressure Pipe
7-1-2 Fired Heaters
4-6-2 Supporting Structures and Foundations for Heavy Machinery
16-3-1 Wiring Methods and Material Selection
CODES AND STANDARDS
ACI
214 Recommended Practice for Evaluation of Strength Test Results of Concrete
301 Specification for Structural Concrete for Buildings
302.1R Guide for Concrete Floor and Slab Construction
305R Hot Weather Concreting
308 Standard Practice for Curing Concrete
309R Guide for Consolidation of Concrete
318 Building Code Requirements for Reinforced Concrete
347 Formwork for Concrete
349 Code Requirements for Nuclear Related Concrete Structures, Appendix B -
Steel Embedments
350R Environmental Engineering Concrete Structures
350.1R Testing Reinforced Concrete Structures for Water Tightness
504R Guide to Joint Sealants for Concrete Structures

AISC
S335 Specification for Structural Steel Buildings: Allowable Stress Design and
Plastic Design with Commentary

ASTM
A36/A36M Carbon Structural Steel
A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and
Steel Products
A153/A153M Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware
A185 Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete
Reinforcement

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A193/A193M Alloy-Steel and Stainless Bolting Materials for High-Temperature Services

TABLE 1 (Cont’d)

ASTM (Cont’d)

A194/A194M Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High
Temperature Service
A775/A775M Standard Specification for Epoxy Coated Reinforcing Steel Bars
A307 Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength
A325 Structural Bolts, Steel, Heat Treated, 120/150 ksi minimum Tensile Strength
A325M High-Strength Bolts for Structural Steel Joints (Metric)
A354 Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally
Threaded Fasteners
A563 Carbon and Alloy Steel Nuts
A563M Carbon and Alloy Steel Nuts (Metric)
A615/A615M Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement
B695 Coatings of Zinc Mechanically Deposited on Iron and Steel
C31 Making and Curing Concrete Test Specimens in the Field
C33 Specification for Concrete Aggregates
C94 Ready-Mixed Cement
C143 Test Method for Slump Hydraulic Cement Concrete
C150 Portland Cement
C156 Test Method for Water Retention by Concrete Curing Materials
C192 Making and Curing Concrete Test Specimens in the Laboratory
C 260 Air-Entrained Admixtures for Concrete
C494 Specification for Chemical Admixtures for Concrete
C 618 Coal Fly Ash and Raw or Calcined Natural Pozzolan for use as a Mineral
Admixture in Portland Cement Concrete

AWS
D1.4 Structural Welding Code for Reinforcing Steel

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#2.2 If local standards exist for the materials, design, and test methods listed in Table
1 which yield comparable quality, they may be substituted provided such
substitutions are acceptable to the authorities where the structure is to be located
and such substitutions have been submitted to and approved by ESSO.

3.0 CONCRETE SELECTION AND MIX DESIGN CRITERIA

#3.1 Before delivery of any concrete, the contractor shall submit to ESSO a statement
covering the properties of the materials and the proportions by weight of cement,
water, aggregates, and additives proposed for each class of concrete required for
the work. The mix designs shall conform to the requirements of ACI 301 and this
Specification . If there is a change in material source or method of mix (ready mix
or jobsite mix) then a new statement shall be issued.

3.2 The water-cement ratio of a concrete mix shall be selected in accordance with
the design requirements, and shall be reviewed for adequacy on the basis of the
type of construction and exposure conditions.

3.3 The water present in the aggregate and any admixtures shall be taken into
account in determining the amount of water in the mix.

#3.4 The Contractor shall show satisfactory evidence to ESSO that the mixes selected
will produce concrete of the desired strength and durability in accordance with the
minimum strength requirements shown in Table 2 and the following:

a. The values shown in Table 2 represent minimum 28-day compressive

strength of normal portland cement concrete (or 7-day compressive strength
of high-early strength concrete) as determined by tests on 150 mm diameter
by 300 mm high (6 in x 12 in) cylinders per ASTM C31 or ASTM C192.

b. If testing is done on cubes, laboratory tests shall be made on both cylinders

and the specified size of cube required by local regulations in order to
establish a correlation with the desired cylinder strength for each design mix.

c. Lacking adequate laboratory facilities for testing such cylinders, the 28-day
compressive strengths of 100 mm, 150 mm, and 200 mm cubes (4, 6, and 8
in) must be at least 130%, 125%, and 120%, respectively, of specified cylinder
strengths.

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3.5 Selection of cement type shall be governed by the following:

a. Cement containing tricalcium aluminate in excess of 15% shall not be used

for structural purposes.

b. Table 3 shall be used in selecting cement types for concrete in continuous

contact with soil or water containing sulfates, and where there is no previous
information on the suitability of specific cement at a particular location.

#3.6 The use of admixtures shall be submitted to ESSO for approval and shall be per
the following:

a. Calcium chloride admixtures shall not be used.

b. Accelerating, retarding, water-reducing, and superplasticizer admixtures shall

be per ASTM C494.

TABLE 2

Application and Compressive Strengths of Concrete

Compressive Strength
Application Mpa psi
a. Prestressed or precast concrete structures 30 4350
b. Precast pipe 25 3625
c. Precast piling
d. Precast concrete sills, copings, and all ornamental
concrete
e. Reservoirs, separators, and septic tanks
f. Girders, beams, walls, slabs, piers, and columns
g. Pipe supports
h. Concrete for fireproofing
i. Concrete on or below grade: such as footings, pile
caps, tie beams, grade beams, anchor blocks, catch
basins, pump blocks , manholes, sidewalks and paving
j. Cast-in-pace piles
k. Concrete for underground electrical duct banks 15 2175
(protective cover, etc.)
l. Low strength concrete for filling purposes where mass,
rather than strength, is the principal requirement

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TABLE 3

Selection of Cement Type for Concrete in Sulfate Exposures

SULFATE SULFATE CONCENTRATION AS CEMENT TYPE MAXIMUM

EXPOSURE SO4 WATER-
CEMENT RATIO
(wt)
In Soil In Solution
% (wt) ppm (mg/L)
Moderate 0.10-0.20 150-1500 II 0.50
Severe >0.20-2.00 >1500 to 10,000 V 0.45
Very Severe >2.00 >10,000 V plus pozzolan (2) 0.45

Notes: (1) Seawater is considered moderate exposure

(2) Use a pozzolan which has been determined by tests to improve sulfate resistance
when used in concrete containing a cement with a maximum tricalcium aluminate
content of 5% or less.

3.7 Concrete aggregate shall meet ASTM C33. The proposed maximum aggregate
size shall be no greater than 38 mm (11/2 in.). Proposed aggregate sources
shall be sampled and tested by Contractor to ensure that durability, soundness,
percentage of clay lumps, graduation, and chemical properties are within
acceptable limits per ASTM C33 to produce the desired concrete.

3.8 Water source shall be tested by a testing agency and shown to be acceptable for
concrete work. Mixing water for concrete shall meet the requirements of ASTM
C94.

3.9 The allowable slump, tested per ASTM C143 at the point of delivery, shall be
within the ranges shown in Table 4:

TABLE 4
Slump (1)
Type of Construction Maximum (2) Minimum
Foundation walls and footings 102 mm (4 in) 51 mm (2 in)
Building slabs, beams, walls, and columns 102 mm (4 in) 76 mm (3 in)
Slabs on grade and heavy mass construction 76 mm (3 in) 51 mm (2 in)

Notes: (1) When concrete pumps are used, the slump shall be determined at the discharge
point of the concrete placement hose.

(2) When a high range reducer is added to increase slump without changing the
water/cement ratio, the slump shall not exceed 200 mm (8 inches) after addition of
reducer.

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Adding additional water to the established mixture to improve the workability is not
allowed. Retempering to compensate for slump loss resulting from delays in
delivery or placing is prohibited.

3.10 Air entrainment agents used in the concrete mix must meet the requirements of
ASTM C260.

3.11 Fly ash used in the concrete mix shall meet the requirements of ASTM C618,
Class F.

#3.12 Contractor shall accommodate ESSO if ESSO elects to survey the Contractor’s
concrete batch plant.

4.0 FORMWORK

4.1 Forms shall conform to the shape, line, and dimensions of the members as
shown on the drawings and shall be sufficiently tight to prevent leakage of
concrete per ACI-318 and ACI-347. Tolerances shall be as recommended in ACI-
301 unless otherwise noted.

4.2 All exposed concrete corners or edges shall be chamfered 19 mm (3/4 in.)unless
noted otherwise on the drawings.

4.3 Under ordinary conditions, forms and supports shall remain in place for not less
than 72 hours after the concrete is placed. Elevated structures supporting loads
other than self weight, such as construction loads, shall be supported for 7 days
after the concrete is placed.

4.4 Forms of suitable materials shall be used to retain the concrete pour without
moving or wrapping. All form work shall be properly cut, spaced, braced, shored,
and accurately aligned.

#4.5 Any parting agent used on forms requires ESSO’s approval and shall be applied
at times or by means that prevent any contamination of reinforcing steel.
Replaceable clean-out openings should be installed at the bottom of columns and
deep walls.

5.0 REINFORCING STEEL

5.1 All reinforcement, at the time of placing concrete, shall be free of loose mill scale,
dirt, oil, or any coating that would adversely affect bonding capacity. All
reinforcing steel shall have a specified minimum yield strength of 414 Mpa
(60,000 psi), and conform to ASTM A615 and ASTM A775 for epoxy coated
reinforcement. All welded wire fabric shall conform to ASTM A185.

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5.2 All reinforcing steel shall be cut and fabricated at the shop before delivery.
Bending reinforcement shall be in accordance with ACI-318. All bars shall be cold
bent. Heating to facilitate bending shall not be permitted. Reinforcing bars shall
be placed to the following tolerances:

a. Clear distance to formed surfaces: 6 mm

b. Minimum spacing between bars: 6 mm
c. Members 200 mm (8 in) deep or less: ±6 mm
d. Members more than 200 mm but less than 600 mm deep: ±13 mm
e. Member more than 600 mm deep: ±25 mm

5.3 Bars shall be fastened together at crossings with a double wrap of annealed 16
gauge wire. Splices shall be made only as required or permitted on the design
drawings and shall have a minimum lap in accordance with ACI-318. Welding of
cross bars for assembly is prohibited.

5.4 Welded wire fabric shall be unrolled and straightened so that it will be flat and kept
in position in the slabs as shown on the drawings. All sheets, at all edges, shall
be lapped one full mesh plus 50 mm (2 in.) and shall be securely wired together
on 400 (16 in.) mm centers or less.

5.5 Reinforcing steel in formed concrete shall be fixed in position by means of pencil
rods, snap bars, wire or approved manufactured spacers so that the clearances
from ACI-318 will be maintained.

5.6 Reinforcing bars left exposed for future connection shall be protected from
corrosion by cement grout or other adequate covering. When placing new
concrete, bar extensions shall be cleaned of loose grout or other covering which
might weaken bond. Concrete surfaces shall be thoroughly cleaned and all
laitance and standing water removed. Vertical construction joints shall be
thoroughly wetted immediately before new concrete is placed.

5.7 Welding of reinforcing steel shall conform to AWS D1.4. Strength welding of
reinforcing bars shall not be permitted for steels in which the sulfur or
phosphorous content exceeds 0.06%, or in which the carbon content exceeds
0.3%.

6.0 EPOXY-COATED REINFORCING STEEL

6.1 When the chloride content of the soil exceeds 1500 PPM epoxy coated reinforcing
steel shall be used.

6.2 Epoxy-coated reinforcing bars shall be inspected for damaged coating when the
bars are received at the jobsite and just before concrete placement.

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6.3 All visible damage to the epoxy-coating due to shipping, handling, bending, cutting,
or placing shall be repaired with patching material conforming to ASTM A775.
Repair shall be done in accordance with the patching material manufacturer’s
recommendations.

6.4 All reinforcement accessories (spacers, chairs, ties, tie wire, stirrups, etc.)
required for spacing, assembling and supporting reinforcement in place shall be
epoxy coated or an approved plastic accessories.

6.5 All reinforcement shall be bent cold and not re-bent. The mandrel (or pin) around
which the bar is bent shall be fabricated from (or covered with a collar of) wood,
nylon, or other non-abrasive material which will not damage the epoxy coating.

6.6 Epoxy coated reinforcing bars shall not be used in the same structure as
uncoated reinforcing bars.

6.7 Handling of epoxy-coated rebar shall conform to ACI-301, ASTM A775, CRSI
Guidelines for Inspection and Acceptance of Epoxy Coated Reinforcing Bars, and
this Specification.

6.8 When epoxy-coated reinforcing bars are cut in the field, the ends of the bars shall
be coated as soon as the bar cutting process is finished, with the same material
used for the repair of coating damage. Flame cutting shall not be allowed.

6.9 Epoxy-coated reinforcement does not need to be used in reinforced concrete in

which the environment, including the mixing water, ground water and soil, does
not pose a corrosive threat to the reinforcement. Proposals to not use epoxy-
coated reinforcement shall be submitted in writing to ESSO.

7.0 ANCHOR BOLTS AND OTHER EMBEDDED ITEMS

7.1 Anchor bolts shall be sized using allowable stresses given in the AISC
Specification; however, no increase in allowable stresses shall be taken when
wind or seismic loads are considered. Anchor bolt sizes determined by this
method, which have not been galvanized, inorganic zinc coated or fluorocarbon
coated, shall have their diameters increased by 3 mm (1/8 in) as a corrosion
allowance.

7.2 Anchor bolts shall have a minimum clearance of 75 mm (3 in) or four bolt
diameters, whichever is greater, from the faces of piers or foundation blocks.
Development of anchor bolts shall be per ACI-349, for bolts with an anchor head,
nut, plate or similar device. Hooked bolts shall not be used. The material used
for anchor bolts shall be as follows:
a. Material for carbon steel anchor bolts shall be per ASTM A36 /A36M or ASTM
A307 unless otherwise specified. The nuts for carbon steel anchor bolts and
headed bolts shall be per ASTM A563M, Grade A, heavy hex. Carbon steel
anchor bolts per ASTM A36/A36M or ASTM A307 shall be hot dip galvanized.

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b. Material for alloy steel anchor bolts shall be per ASTM A354, Grade BC,
unless otherwise specified. The nuts for A354 bolts shall be per ASTM A563
Grade DH(heavy hex) or ASTM A563M Class 105 (heavy hex). Alloy steel
anchor bolts per ASTM A354, Grade BC, shall be hot dip galvanized in
accordance with ASTM A153/A153M Class C.

c. When anchor bolts are likely to be subjected to elevated temperatures

significantly above normal atmospheric temperatures or anchor bolts subject
to severe dynamic loads or structures subject to high tension loads (e.g. tall
towers), the alloy bolting material shall be per ASTM A193, Grade B7, and the
nuts shall be per ASTM A194, Grade 2H, heavy hex. Alloy steel anchor bolts
per ASTM A193, Grade B7 cannot be hot dip galvanized and cannot be
welded to other steel.

# d. The sizes of anchor bolts shall be in the same units as the base plates or
equipment that it connects. Mixed units are not allowed unless approved by
ESSO.

7.3 Anchor bolts shall be set true to the lines and grades shown on the drawings
using a template where possible and shall be set plumb and securely based to
prevent displacement during the placing of concrete. Anchor bolt threads shall be
protected by encasing them in burlap or paper and coating them with grease.
Upon the completion of concrete placement, Contractor shall recheck all anchor
bolts for correct location and elevation. Anchor bolts shall be plumb within 1.5
mm (1/16 in.) of the position on the design drawings. If any bolt exceeds this
tolerance, Contractor shall make appropriate corrections.

7.4 At completion of the inspection, Contractor shall clean out all anchor bolt sleeves,
remove thread encasing materials, wire brush, and thoroughly grease the threads
and replace washers and nuts.

7.5 Expansion anchors shall be marked at their exact location on the surface of the
cured concrete. Procedures and tools used for the expansion anchor installation
shall be in accordance with manufacturer’s recommendation.

7.6 When anchoring to existing concrete, expansion type anchors shall not be used
when anchoring rotating equipment, and in any other application where the anchor
bolts will be subjected to vibratory loads.

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7.7 All embedded curb angles, beams, frames, and pipe sleeves shall be set true to
the lines and grades shown on the drawings. Embedded items shall be secured
and braced to prevent shifting during concrete placement. Before placing
concrete, curb angles and frames shall be field-welded and the weld ground flush.
After completion of the concrete pour, the exposed surfaces of the embedded
items shall be cleaned of concrete, oil, or other matter, the shop coat primer shall
be retouched as required.

7.8 All embedded items shall be free of loose scale or rust, dirt, oil, or any coating that
would affect bonding prior to setting.

8.0 DELIVERY

8.1 Adequate manpower and equipment shall be available for rapid, continuous
placement of concrete. Preparation before conveying concrete shall be in
accordance with ACI 301.

8.2 Concrete shall be conveyed from concrete truck or mixer to final deposit by
methods that prevent segregation, slump loss, or loss of materials.

8.3 Equipment such as chutes, concrete bucket, pumps, tremies, or conveyor belts
shall be of the size and design to ensure a continuous flow of concrete at the
point of placement and shall not be supported by forms or reinforcement.

9.0 PLACING

9.1 Just prior to placement of concrete, forms shall be cleaned of all debris, sand,
and standing water. Preparation before placement of concrete shall be in
accordance with ACI 301.

9.2 Concrete shall be deposited at or near its final position, eliminating the tendency
to segregate when it has flowed laterally into place per ACI-309R. Concrete shall
be moved by shovel and come-alongs. No rakes shall be used in concrete
placement.

9.3 On sloping surfaces, concrete placement shall start at the lower portion of the
slope and progress upward.

9.4 No concrete that has partially hardened or been contaminated by foreign material
shall be placed in the forms.

9.5 Concrete shall not be dropped freely from a height of more than 2 meter (6.5 ft.)
and shall be distributed in uniform layers not to exceed 0.6 meter (2 ft.) in height,
avoiding inclined layers and cold joints.

9.6 Slabs and beam systems shall be placed in one operation.

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9.7 Concreting, once started, shall be continuous until a section is completed.

9.8 Construction joints may be placed only where designated on design drawings or 6
meters center to center, maximum.

9.9 All concrete shall be thoroughly consolidated by vibrators, working concrete

around reinforcement and embedded fixtures and into corners of the forms.
Vibrators shall be adequately sized as per ACI-309R, Table 5.1.5. When
reinforcement is epoxy coated, vibrators shall have a rubber sleeve.

9.10 Vibrators shall not be used to move concrete laterally. Vibrators should be
inserted and withdrawn vertically at intervals of 5 to 20 seconds duration and at
points 0.5 to 0.75 meter (20 in. to 30 in.) apart, penetrating previously placed fresh
concrete. Only incidental contact with reinforcing steel will be permitted.
Excessive vibrating shall not be permitted.

10.0 HOT WEATHER CONCRETING

10.1 For this Specification, hot weather is defined as any combination of high air
temperature, low relative humidity, and wind velocity tending to impair the quality
of fresh or hardened concrete.

10.2 Concrete temperatures at time of placement shall be limited in accordance with

Figure 2.1.5, from ACI-305, so that the evaporation rate of the mixing water shall
not exceed 0.2 pound per square foot per hour. In no case shall the temperature
of concrete delivered at the job site exceed 32ºC (90°F).

10.3 One or more of the ingredients may have to be cooled to keep the concrete
temperature from being excessive at the time of placement. An equal mass of
crushed ice may replace part of the mixing water. The ice shall be added directly
to the mixer and shall be completely melted by the time mixing is completed.

10.4 Time period between mixing and placing shall be as short as possible to avoid
slump loss and cold joints. Concrete shall not stand in rotating mixer longer than
1 hour and 15 minutes.

10.5 Provisions shall be made for wind breaks, shading, fog spraying with sweet water
or raw water with not more than 500 parts per million of chlorides nor more than
1000 parts per million of sulphate, or wet cover on fresh concrete when
necessary to prevent rapid moisture loss.

10.6 Subgrade, forms, and reinforcing steel shall be dampened prior to placement of
concrete. Excess water shall be removed just before concrete placement
begins. Where possible, cooling shall continue during placement.

#10.7 An admixture meeting ASTM C494 retarder requirements (Type D water-

reducing) may be used in hot weather concrete subject to approval by ESSO.

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10.8 The spray application of a monomolecular finishing aid to prevent loss of moisture
in fresh concrete may be applied immediately to all horizontal concrete surfaces
following screening, at the rate of not less than 2.2 liters of sprayable solution per
square meter. Use of a monomolecular finishing aid does not eliminate curing
requirement per this Specification.

11.0 EXPANSION JOINTS AND CONSTRUCTION JOINTS

11.1 Expansion joints shall be the sizes and types shown on the drawings and shall be
placed at locations as shown on the drawings. Exposed edges of finished
concrete in slabs shall be edged to prevent crumbling at joints. Expansion joints
shall have smooth dowel which are free to move on one half of the joint. The gap
width shall be 20mm (3/4 in.), filled with a non organic compressible material and
sealed on the top.

11.2 Joint sealing when specified shall be done within 10 days after concrete has been
finished in any particular area. Excess sealing material shall be removed so that
the joint conforms to the drawings. Joints in concrete water retaining structure
shall conform to ACI-350.

11.3 Control or construction joints not specified on the design drawings shall be
located at the column centerlines and at intermediate intervals so that each panel
does not exceed 56 m2 (600 ft2) in area. Concrete shall be placed in alternate
paving lanes utilizing construction and control joints as specified.

11.4 Reinforcement shall be continued through construction joints.

11.5 Construction joints in walls shall be no more than 30.5m (100 ft.) apart. Install
weakened plane control joints at 7.62m (25 ft.) maximum spacing between
construction joints.

12.0 FINISHING

12.1 All concrete floors and slabs shall be classified by intended use per Table 1.1 of
ACI-302.1R. Tools and finishing procedures for each class shall be in
accordance with Chapter 7 of ACI-302.1R.

12.2 Areas subject to foot traffic shall receive a nonskid finish by drawing a fine, soft-
bristle broom over the troweled surface. Edges and joints shall be tooled.

12.3 All concrete floors and slabs shall be leveled with a screed and finished to a
tolerance of 1.5 mm in 1 meter. Surface irregularities in excess of these
requirements shall be corrected.

13.0 PATCHING AND REPAIR OF SURFACE DEFECTS

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13.1 Tie holes, honeycombs, and other concrete surface defects shall be repaired in
accordance with ACI-301 after form removal and in such a manner as will not
delay, interfere with, or impair the proper curing of the fresh concrete.

#13.2 Prepackaged grouts and patching compounds may be used after ESSO approval
is obtained.

13.3 Remediation of Out-Of-Tolerance Slabs is as follows:

a. Grind down high points.

b. Raise low points by using the specified underlayment compound or repair

topping if the areas are exposed.

c. Critical slab areas shall be replaced if “out-of-tolerances” exceed those

identified on drawings.

1. Demolish and replace critical out-of-tolerances areas.

#2. Submit demolition and replacement plan to ESSO for approval before
demolition.

3. Replacement slab shall meet tolerance requirements.

13.4 Major structural defects shall be reconstructed with concrete of the same
composition as the adjacent concrete, and the repairs shall receive additional
curing.

14.0 CURING

14.1 Curing and protection of fresh concrete shall start immediately after final finishing
operations. Curing methods and materials shall be in accordance with ACI-308.
Concrete shall be protected from premature drying, temperature extremes, and
mechanical injury for at least 7 days to allow proper hydration of the cement and
hardening of the concrete.

14.2 Moisture loss from surfaces adjacent to forms shall be minimized by keeping the
forms wet until they can be safely removed. Concrete shall be kept moist for a
minimum of 7 days or until 70 percent of the specified strength has been
achieved, whichever is longer.

14.3 All materials and facilities for curing concrete shall be on hand and ready for use
before concrete is placed and shall be tested per ASTM C156.

15.0 PAVING

*15.1 The extent of paving and toe walls within process areas to control spillage, and for
drainage of storm, process and fire water will be as specified on the drawings.

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*15.2 Areas where corrosive chemicals are present shall have paved areas around
pumps and other equipment and toe walls shall be coated as specified.

16.0 CONCRETE STRUCTURES

16.1 Concrete shall be designed and constructed per ACI 301 and ACI 318 standards.

#16.2 For in-ground structures the safety factor against flotation shall be not less than
1.2 for both normal operation and erection.
Buoyancy forces shall be calculated with the ground water level assumed to be at
the finished grade elevation. Pressure relief systems, deliberate flooding, or other
extraordinary methods to prevent flotation shall not be used unless approved by
ESSO.

16.3 For construction joints the following procedure shall be used when bonding new
concrete to existing concrete:

a. Break out or roughen the surface of the existing concrete and join existing
reinforcing bars to new steel by splicing or welding.

b. All loose materials shall be removed. The surface of oil/grease contaminated

joints and reinforcing steel shall be thoroughly cleaned and degreased with a
proper solvent.

c. Coat the entire contact surface of the existing concrete with epoxy adhesive
Escoweld No. 7502, or approved equal, in accordance with the manufacturers
procedure.

17.0 LIQUID RETAINING STRUCTURES

17.1 Liquid retaining structures shall include in-ground concrete pits exposed to
groundwater and above-ground or in-ground concrete structures required to
contain liquids.

17.2 Liquid retaining structures shall be designed and constructed for liquid tightness
according to the provisions of ACI 350, except that the structural design
considerations shall be as clarified in paragraphs 17.3 and 17.4.

17.3 To minimize cracking and leakage, the design of concrete walls, slabs and other
elements which serve to retain liquids shall be in accordance with the following
criteria:

a. Minimum thicknesses and changes in thickness shall be as follows:

1. Walls shall have a minimum thickness of (100+67 H) mm [(4+0.8 H) in]

but not less than 200 mm (8 in) where H equals the wall height in meters
(feet).

2. Slabs shall have a minimum thickness of 250 mm (10 in).

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3. Changes in wall or slab thickness shall be accomplished using tapered

sections having a minimum length of three times the change in thickness.

b. Reinforcement shall conform to the following criteria:

1. Reinforcing bar diameters shall not exceed 6% of the thickness of the wall
or slab.

2. Reinforcing bar spacing shall not exceed 300 mm (12 in).

c. Area of shrinkage and temperature reinforcement in each direction shall be a

minimum of 0.3% of the gross concrete area for slabs and walls 300 mm (12
in) or less in thickness. For slabs and walls more than 300 mm (12 in) thick,
minimum reinforcement shall be as specified in ACI 318, Sections 7.12.2 for
slabs; and 14.3 for walls, with a minimum of 15 mm diameter bars (#5 bars),
300 mm (12 in) on center in faces of exposed walls.

d. Maximum reinforcement stress, fs, at service loads shall be as follows:

1. fs≤96.5 Mpa (14 ksi) for members subjected to direct tension.

2. fs≤207 Mpa (30 ksi) for Grade 60 bars in members subjected to bending.

e. Distribution of flexural reinforcement shall be limited by the quantity Z as

follows:

Z ≤ 0.0166 MN/mm (95 kips per inch) for severe exposure(1)

Z ≤ 0.0201 MN/mm (115 kips per inch) for normal exposure(2)

where:
Z = fs(dcA)1/3
fs = calculated stress in reinforcement at service loads, Mpa (ksi)
dc = thickness of concrete cover measured from the extreme tension fiber
to center of the closest bar, mm (in)
A = effective tension area of concrete surrounding the flexural tension
reinforcement and having the same centroid as that reinforcement,
divided by the number of bars, mm2 (in2). When the flexural
reinforcement consists of different bar sizes, the number of bars shall
be computed as the total area of reinforcing steel divided by the area
of the largest bar used.
Notes: (1) Severe exposure is exposure to corrosive soils, liquids or condensate, plus wetting and
drying.
(2) Normal exposure is exposure to non-corrosive substances.

f. Maximum reinforcement spacing shall be as per Table 5.

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TABLE 5
BAR SIZES MAXIMUM SPACING, S
mm (No.) mm in
15 & 20 (#3, 4, 5) S ≤ (Z/fs)3 S ≤ (Z/fs)3
4238.7 6.57
20 & 25 (#6, 7, 8) S ≤ (Z/fs)3 S ≤ (Z/fs)3
8064.5 12.5
30 & 35 (#9, 10, 11) S ≤ (Z/fs)3 S ≤ (Z/fs)3
9438.7 14.63

g. Maximum concrete stresses at service loads shall be as per Table 6.:

TABLE 6
TYPE OF STRESS MINIMUM CONCRETE STRESS
AT SERVICE LOAD
kPa psi
Flexure; fc
Extreme fiber stress in compression 9300 1350
Extreme fiber stress in tension in plain
concrete footings and walls 605 88

Shear v (as measure of diagonal tension at d from

face of support)
Beams with no web reinforcement 410 60
Joists with no web reinforcement 455 66
Members with web reinforcement or properly
combined bent bars and vertical stirrups 1890 274
Slabs and footings (peripheral shear) 760 110
Bearing:
On full area 5170 750
One one-third area or less 7755 1125

h. Expansion joints shall be spaced not more than 15 m (50 ft) apart for exposed
members and not more than 24 m (80 ft) apart for members completely
underground.

i. Construction joints shall be spaced not more than 4.5 m (15 ft) apart vertically
and not more than 9.0 m (30 ft) apart horizontally. Reinforcement shall be
continuous through the joint. A shear key at least 38 mm (1-1/2 in) deep with
a width of at least one-third the thickness of the wall or slab shall be provided.
Waterstops shall be provided at construction joints which must be watertight.

#j. Construction joints not shown on the drawings shall be submitted to ESSO
for approval.

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17.4 Construction of liquid retaining structures shall conform to ACI 301 and the
following:

a. Waterstops shall be firmly tied to the reinforcement or forms to prevent

movement during concreting.

b. Concrete shall not be allowed to drop more than 1 m (3 ft) vertically and shall
be placed as nearly as practicable in its final position to avoid segregation.

c. The surface of the concrete at all joints shall be thoroughly cleaned and all
laitance removed before placing adjoining concrete.

d. For horizontal joints, new concrete shall be placed on a layer of cement

mortar that has been evenly spread over the previously placed concrete.

#e. Curing methods shall require ESSO’s approval.

18.0 REINFORCED CONCRETE FOUNDATIONS

#18.1 Allowable soil bearing pressures shall be based on the results of a soils
investigation, and a consideration of permissible total and differential settlements.
The allowable soil bearing pressure requires ESSO’s approval.

18.2 Footing size and shape shall be determined by settlement considerations if

specified, or by the following criteria:

a. Under the action of vertical or lateral loads, or both, with loading combinations
which result in maximum vertical load or overturning moment, or both, the
maximum soil pressure shall not exceed the applicable allowable value.

b. Under the action of vertical loads and overturning moment, the ratio of
stabilizing moment to overturning moment shall not be less than 1.5 for
erection, and 1.8 for all other conditions.

c. For foundations bearing on cohesionless soil supporting towers or other

slender structures with heights greater than 30 m (100 ft) and a ratio of total
height to skirt or base diameter greater than 10; 85% of the foundation shall be
in compression for the design overturning moment during erection and 100%
of the foundation shall be in compression for the design overturning moment
during normal operation.

18.3 Top of concrete shall be a minimum of 300 mm (12 in) above finished grade or
high point of paving for foundations under the following equipment:

a. Steel column bases of open structural framing.

b. Pipe supports.

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c. Pumps, fans, compressors, and legs or skirts of towers, drums and

exchangers.

18.4 For commercial or industrial type buildings, the top of concrete piers shall be flush
with the floor, unless otherwise specified by the building supplier.

18.5 Piers under base plates and pedestals supporting vessels with skirts shall extend
38 mm (1-1/2 in) minimum beyond the base plates, or skirt base rings and lugs,
in all directions.

18.6 Piers and pedestals shall be reinforced to resist thermal stresses due to
expansion of base plates, soleplates, rails, skirt base rings and lugs, anchor bolts,
and concrete. Pedestals are supports having a ratio of height to least width
dimension of not more than 3. Piers are supports with a ratio of height to least
width dimension of 3 or more. As a minimum, vertical reinforcement shall be tied
as follows:

a. In piers, vertical reinforcement shall be enclosed in lateral ties per ACI 318
requirements for tie reinforcement for columns.

b. In pedestals, vertical reinforcement shall be enclosed by complete

circumferential ties meeting the size and spacing requirements per ACI 318
for tie reinforcement for compression members.

c. The spacing between the top two ties in piers and pedestals shall not be more
than 100 mm (4 in).

18.7 Concrete in piers and pedestals, and grout shall not extend above the bottom face
of base plates, soleplates, rails, skirt base rings and lugs.

18.8 Pedestals for vessels with skirts shall have the area within the skirt sloped for
drainage, and a suitable embedded pipe or opening in the grout provided
discharging to the pavement outside the skirt.

18.9 Foundations supporting rotating equipment not classified as heavy equipment

shall be as follows. For heavy machinery requirements refer to CCS 4-6-2.

a. The minimum ratio of concrete to weight of equipment shall not be less than
3:1 for rotating equipment and 5:1 for reciprocating equipment.

b. In addition to reinforcing steel required by design, a minimum of two rows of

ties shall be provided around anchor bolts in the top of machine pedestals. A
horizontal layer of temperature steel shall be provided in the top of pedestals
or slabs.

18.10 There shall be no pipelines, sewers, or conduit located within a zone bounded by
the bottom of the foundation and planes projected 45º downward and outward
from the bottom edge of the foundation.
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19.0 UNDERGROUND PROTECTIVE CONCRETE

19.1 All concrete used for underground electrical work shall be per CCS 16-3-1.

19.2 Thrust blocks for underground cast iron and non-metallic pressure pipe shall be
cast-in place concrete per CCS 3-7-3

19.3 All concrete used for underground air ducts for fired heaters shall be per CCS 7-
1-1.

#19.4 Concrete duct designs for air temperatures greater than 93°C (200°F) shall be
submitted to ESSO.

20.0 INSPECTION AND TESTING

20.1 Concrete materials and operations shall be tested and inspected as the work
progresses in accordance with Chapter 16 of ACI 301.

20.2 Concrete requiring a compressive strength of 25 Mpa (3625 psi) or more shall be
tested in accordance with ACI 318 except as follows:

a. One test shall be taken for each day’s pour and at least one test shall be
taken for each 38 m3 (50 cubic yards) placed. In addition, at least one test
shall be made for each foundation exceeding 15 m3 (20 cubic yards). Take
additional samples when observations indicate nonconformance.

b. A test shall consist of three cylinders made and cured in the field according to
ASTM C31. One such cylinder shall be tested in the laboratory after seven
days and one after 28 days with results submitted to ESSO as soon as
possible. Testing of the remaining cylinder shall be performed if the concrete
strength is in question.

c. Slump test on concrete shall be performed at the time of concrete placement

at a rate of one test per every 15 m 3 (20 cubic yards).

#20.3 Concrete showing structural defects shall be demolished and replaced. Concrete
showing surface defects shall be patched. Structural members shall not be
demolished without prior notification and consent of ESSO.

#20.4 Liquid retaining structures shall pass a water-tightness test which shall be
submitted to ESSO. Repairs which affect the water-tightness of the structure
require prior approval by ESSO.

21.0 EVALUATION AND ACCEPTANCE

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21.1 Evaluation of all compressive strength data shall be done in accordance with ACI-
214.

21.2 Upon testing and evaluation, concrete shall be considered acceptable if the
following criteria are met:

a. Not more than 10 percent of the 28-day strength tests shall have values less
than the specified fc.
b. The average of strength tests from any three consecutive pours shall be equal
to or greater than the specified strength fc.
c. No individual strength test is more than 3.4 Mpa (500 psi) below the specified
strength fc.

21.3 If the structural adequacy is in doubt, contractor shall take remedial action
appropriate to the circumstances.

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