KOC-C-006

~I J~I ~.:.I-t".J. .s~1 ,. Subsidiary of Kuwa~ Petroleum Corporation

STANDARDS PUBLICATION

KOCSTANDARD

FOR

CONCRETE WORK­ MATERIALS AND CONSTRUCTION

DOC. NO. KOC-C-006

(Revision 2)

(FORMERLY 015-QH-IOOI & DES-C-002)

STANDARDS TEAM

REV.2

Page 1 of

STANDARDS PUBLICATION

KOC STAN

RD

FO

CONCRET

RK­

ATERIALS AND C NSTRUCTION

DOC.NO. K

- -006

STANDARDS TEAM

Ilbll==D=O=C=.N=O=.=K=OC=-=C-=OO=6==~II====pa=g=e=2=Of=7=5====~II=======R=EV=.2======~1

KOC STANDARD

FOR

CONCRETE WORK ­ MATERIALS AND CONSTRUCTION

DOC.NO. KOC-C-006

(FORMERLY 01S-QH-1 001 & DES-C-002)

ISSUING AUTHORITY:

STANDARDS TEAM

2

Rev.

30.05.11

Date

Revised & re-Issued as

Task Force

KOC Standard

(TF-C/13 )

Description

Prepared by

()

-

Snr. Engr. Standards. Tel. 61407

~~

....

"'"-'-

. Team Leader Standards Tel. 61161

.

DOC. NO. KOC-C-006

Page 3 of 75

Il

REV.2

TABLE OF CONTENTS Page No. FOREWORD

6

1.0

SCOPE

8

2.0

APPLICATION

8

3.0

TERMINOLOGY

8 8

3.1 3.2 4.0

Definitions Abbreviations

REFERENCE STANDARDS, CODES AND SPECIFICATIONS

4.1 4.2 4.3

Conflicts List of Standards, Codes and Specifications KOC Standard Drawings

11 12 12 12 23

5.0

ENVIRONMENTAL CONDITIONS

23

6.0

HEALTH, SAFETY AND ENVIRONMENT

23

7.0

8.0

9.0

BASIC MATERIALS REQUIREMENTS

24

7.1 7.2 7.3 7.4 7.5 7.6 7.7

24 24

26 27 30 31 32

CONSTRUCTION REQUIREMENTS

33

8.1 8.2

33 33

General Normal Concrete Proportioning

CONCRETE MIX REQUIREMENTS

9.1 9.2 9.3 9.4 9.5 9.6 10.0

General Portland Cements Cement Replacements (CR) Aggregates Water Admixtures Storage of Materials

Concrete Grades Design Strengths Free Water-Cement Ratio Slump Initial Setting Time Total Salt Content

34 34 34 35 35 36 36

CONCRETE TRIAL MIX

37

10.1 10.2 10.3

37 38 38

Design Mixes for Structural Concrete Design Mixes for Blinding Concrete Absorption Tests

III

DOC. NO. KOC-C-006 11.0

II

Page 4 of 75

FORMWORK 11 .1 General 11.2 Material 11 .3 Design and Installation 11.4 Preparation of Form Surfaces 11 .5 Removal of Forms 11 .6 Tolerances

II

REV.2

39

39

39

39

40

40

41

12.0

REINFORCEMENT 12.1 General 12.2 Reinforcing Bars 12.3 Welded Wire Fabric 12.4 Certification 12.5 Shipping and Storage 12.6 Fabrication 12.7 Cover 12.8 Placing of Reinforcing Bars 12.9 Tolerances for Placement 12.10 Cleaning of Reinforcement

41

41

41

42

42

42

43

43

44

44

44

13.0

CONCRETEPRODUCnON 13.1 General 13.2 Batching 13.3 Mixing 13.4 Concreting in Hot Weather 13.5 Dry Mix Concrete

45

45

45

45

46

47

14.0

CONVEYING, PLACING AND FINISHING 14.1 Conveying Concrete 14.2 Reinforcements and Embedded Items 14.3 Concrete Joints 14.4 Placing Concrete 14.5 Consolidating Concrete 14.6 Bonding Concrete 14.7 Finishing Concrete Surfaces 14.8 Concrete Pour Card

47

47

48

48

49

50

51

51

53

15.0

CURING 15.1 General 15.2 Curing Methods 15.3 Duration of Curing 15.4 Formed Surfaces 15.5 Curing Compound 15.6 Protection from Mechanical Injury

53

53

54

54

54

55

55

16.0

TESTING FOR QUALITY CONCRETE 16.1 General 16.2 Testing Laboratory 16.3 Testing of Materials 16.4 Testing of Freshly Mixed Concrete 16.5 Testing of Hardened Concrete

56

56

56

56

58

62

DOC. NO. KOC-C-006

Page 5 of 75

II

REV.2

II

17.0

REMEDIAL WORK

64

18.0

PROTECTION TO CONCRETE SURFACES 18.1 Protection Below Ground Level 18.2 Protection Above Ground Level 18.3 External Surfaces Exposed to Saline Waters

65 65 65 66

19.0

READY -MIXED CONCTRETE

66

20.0

PRECAST CONCRETE 20.1 General 20.2 Marking 20.3 Curing . Maturing and Stacking 20.4 Cement Sand Mortar

67 67 67 67 67

21.0

WATER-RETAINING CONSTRUCTION 21 .1 General 21 .2 Joints 21.3 Coating 21.4 Testing

68 68 68 69 69

22.0

ANTI-TERMITE TREATMENT

69

23.0

QUALITY CONTROL 23.1 Quality Plan Quality Control Engineer 23.2

70 70 71

24.0

QUALITY ASSURANCE

71

25.0

DOCUMENTATION General 25.1 25.2 Work Records and Reports Deliverables 25.3

71 71 72 72 74

ACKNOWLEDGEMENT

SUMMARY OF CHANGES IN REV.2

SI.

Clause No.

No. 1 4.2

3

4.2.4 6.0

4

7.7.1(d)

2

121

Description of the Major Changes

Updated generally list of Standards. Codes and Specifications. Added new standards as referred. Added US Specifications from Corps of EnQineers Revised HSE clauses and added new requirement in clauses 6.3 -6.8 of this Standard . Added the requirement of ventilation system to control dust particles within limits in the worksite and in the storage areas ..

Page No. 12-22

23 23 32

Page S of 75

FOREWORD

REV.2

I2 I

The previous document "KOC Standard for Concrete Work - Materials and Construction" (KOC-C-OOS Rev.1), issued in Oct.'03) has been updated and generally revised now for conformance with the latest revisions of relevant Int'I I National Standards. It is intended to address the need for consistent and practical requirements for materials, construction, testing and quality control of concrete work within KOC Facilities. This present KOC Standard (Rev.2) has been approved by Standards Team, in consultation with the Standards Technical Committee (STC) for consistent use by KOC User Teams throughout the corporate engineering and operational functions of Kuwait Oil Company (K.S.C) within Kuwait. The purpose of this Standard (Rev.2) sets out to achieve the following objectives: a.

To update the applicable and appropriate Int'I I National Standards listed in this KOC Standard.

b.

To update the appropriate specifications of the basic materials for making plain and reinforced structural normal-weight concrete, which are widely used in concrete construction.

c.

To define minimum technical requirements for producing sound concrete of specified strengths, types and quality for various applications with a view to achieving high performance concrete in construction.

d.

To provide general technical inputs and guidance for developing project specifications and design I construction drawings in order to ensure reliable and durable concrete work.

e.

To assist the engineers by giving an access to the necessary level of documented technical information with a view to optimizing their efforts and productivity.

f.

To set out minimum requirements for monitoring compliance of materials to be used, concrete quality, testing and workmanship with a contract.

Feedback as well as any comments or suggestions from the application of this Standard derived at any stage of engineering, material selection, procurement, testing, quality control, concrete production and workmanship are encouraged and should be directed to: The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P.O. Box - 9758, Ahmadi 61008 State of Kuwait

II

DOC. NO. KOC-C-006

I

Page 7 of 75

Task Force Responsible for this Standard

REV.2

II

I 21

The revision of this Standard (Rev.2) has been entrusted by the Standards Technical Committee (STC) to the Task Force No. (TF-C/13) comprising of the following members:

51. No.

Name of Task Force Members

Responsibilities

Tel. No.

Standards Team

Task Force Leader

61407

Design Team

Member

61322

Construction Team

Member

61297

Gen. Projects Team

Member

66987

KOC Teams

1

Mr. S. Kumar

2

1VIr. Mohd. Javaid

3

Mr. Ahmed Quraishi

4

Mr. David Wijeratne

5

Mr. Brian Robb

PMC (Fluor)

Member

61852

6

Mr.Farahbakhsh Behnam Mr. Omar Warrich

PMC (Amec)

Member

61143

PMC (WPK)

Member

63158

7

Page 8 of

1.0

SCOPE

1.1

This specifies the minimum technical requirements of the basic materials, proportioning, mixing, transporting, placing, curing, testing and quality control for of and durable concrete, as well as sound workmanship for Concrete Work in construction at the KOC onshore facilities within Kuwait.

1.2

This Standard covers only the plain, and reinforced structural mixed and concrete in This that

1

a. b. c. d. e. f.

as a

requirements of normal-weight concrete for work by using normal and I or and water retaining concrete construction.

f""" .... f"r,aTC

shall not be applicable to any structure or any part of the structure of construction any of the following:

Concrete Lightweight Concrete Heavyweight Concrete Insulating Concrete Refractory Concrete Fireproofing Concrete

2.0 1

and of concrete work requirements of this Standard and the reference

2.2

Any exceptions or deviations from this Standard, justifications, shall be brought to the attention of review, consideration and amendment by Standards

2.3

Compliance with this obligations.

not of

conform to and codes mentioned

with their meriT'" Controlling Team for their (if required). immunity from legal or

3.0

3.1 For the purposes of this Standard, the following definitions apply. 3.1.1

Admixture A material/chemical than water, hydrauliC and reinforcement, used as an ingredient of rr".... rr,cTc or mortar, and to the specific batch immediately or during its to achieve one of purposes, such as retarding, water reducing or air entraining as required; and it is called accordingly.

REV.2

Page 9 of75

3.1

Reaction between (potassium and sodium) in the Portland siliceous rocks or minerals, such as chert, strained quartz, and volcanic glass, in some that may cause abnormal expansion and cracking of concrete in service.

3.1

Bleeding autogenous flow of mixing water within, or its emergence from, newly placed or mortar; by the settlement of the solid materials within the mass. n("'roTo

3.1.4

Characteristic Strength population

Value of cube strength, below which 5% of for strength measurements of the volume of concrete

are expected to fall.

1.5

of , crushed or partially crushed, shall be mainly on a 5.0 mm BS 810 sieve or as per ASTM material 1 and shall contain no more sizes specified.

rnnr.",,,,

Contractor Any approved or company complete construction concrete work.

3.1 7

test

Coarse Aggregates aggregates or crushed stones mm (NoAa) than is permitted for

3.1

IJVi:,;:> ...... v

by

Koe,

who are undertaking the

Design Mix Mix for which the purchaser is responsible for specifying the required the mix proportions to produce and the producer is responsible for required performance.

3.1

Durability The ability to resist

other conditions in the working integrity with satisfactory performance during its

3.1

attack, abrasion where it " , e n l l r e life.

Fine Fine shall

comprise of crushed gravel, crushed stone or natural sand, and 410 test and shall contain no more through a 5.0 mm than is for the various grading specified.

DOC. NO. KOC-C-006

REV.2

Page 10 of 75

As per ASTM E11, aggregates passing the 9.5 mm (3/8 in) sieve and almost entirely passing the 4.75 mm (No.4) sieve and predominantly retained on the 75 ).!m (No. 200) sieve. 3.1.10

Fineness Modulus A factor obtained by adding the total percentages of material in the sample that are coarser than each of the following sieves (cumulative percentages retained), and dividing the sum by 100: 150 ).!m (No.1 00), 300 ).!m (No. 50), 600 ).!m (No. 30), 1.18 mm (No.16), 2.36 mm (No.8), 4.75 mm (No.4), 9.5 mm (1/8 in), 19 mm (3/4 in), 37.5 mm (1 1/ 2 in), 75 mm (3 in), 150 mm (6 in).

3.1.11

Heat of Hydration Heat evolved by chemical reactions with water during the setting and hardening of Portland cement.

3.1.12

Normal-weight Aggregate 3

Aggregate with an oven-dry particle density greater than 2000 kg/m but less than 3000 kg/m 3 , when determined according to BS EN 1097-6. 3.1.13

Normal-weight Concrete 3

Concrete having an oven-dry density greater than 2000 kg/m but not exceeding 3 2600 kg/m . 3.1.14

Portland Cements Portland cements are primarily produced from a mix of main minerals in different proportions such as, Lime (CaO), Silica (Si0 2), Alumina (AI 20 3), and Iron oxide (Fe203) by burning them in a kiln; and are composed of four (4) principal compounds with chemical formulas and abbreviations as below: Tricalcium Silicate - 3CaO·Si0 2 Dicalcium Silicate - 2CaO'Si0 2 Tricalcium Aluminate - 3CaO'AI 2 0 3 Tetracalcium Aluminoferrite - 4CaO'AI 2 0 3'Fe 2 03

=C3S

=C2 S

= C~ = C4 AF



These four compounds hydrate with appropriate amount of water to form cement paste and when added to aggregates like sand and gravel or other granular materials, bind them together to form a stone like mass (concrete) and on curing develop the basic characteristics of concrete in relation to their proportions. 3.1.15

Pozzolan A siliceous or siliceous and aluminous material, which in itself possesses little or no cementitious value but will, in finely divided form and in presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties.

110f75

3.1.16

Cement It is a siliceous material, not cement and will react with water in presence of lime or other alkaline to form a cementitious material; generally added to in small as cement for improving performance of like reducing rate of and minimizing risk of alkali-silica reaction

3.1.17

Ready-mixed Concrete ingredients of concrete mixed in a stationary mixer or in a truck-mixer, and concrete delivered in a fresh state to the site in vehicles in the ready-to-use condition.

3.1.18

Silica Fume Very fine pozzolonic material, composed mostly of amorphous (non-crystalline) production of silica produced by arc furnaces as a byproduct of elemental silicon or alloys containing silicon, is used as replacement up to certain percentages to improve properties of concrete.

1.19 Water-Cement by the aggregates Ratio of the mass of free water, excluding that water in a saturated dry condition, to the mass of cement in a concrete mix. 1

Workability property of freshly mixed concrete or mortar, which determines the ease and homogeneity it can be mixed, placed, consolidated, and finished.

CR fck

HSE HSEMS ITP KOC MSDS NDE OPC OSHA PFA PIM PQR QAJQC

SF SRPC WPS

Cement Replacement Characteristic Strength of Concrete Health, Safety and Environment Safety and Environment Management & Test Plan Oil Company (K.S.C) Material Safety Nondestructive Ordinary Portland Occupational Safety and Health Administration Pulverized Fuel Ash Pre-Inspection Meeting Procedure Qualification Records Control Assurance I Silica Fume Sulphate Resisting Portland Cement Welding Procedure Specification

III

DOC. NO. KOC-C-006

II

Page 12 of 75

REV.2

II

4.0

REFERENCE STANDARDS, CODES AND SPECIFICATIONS

4.1

Conflicts

4.1.1

In the event of conflicts between this Standard and the standards / codes referenced herein, or other contractual requirements, the most stringent requirement shall apply. In case further clarifications are required, the subject shall be brought to the attention of KOC Controlling Department.

4.1.2

In general, the order of precedence shall be followed as: a. b. c. d. e.

4.2

Kuwait Governmental Rules and Regulations KOC Technical Specifications This KOC Standard (KOC-C-006) International codes and standards Contractor's standards and specifications

List of Standards, Codes and Specifications

I2 I

The latest edition of the following standards, codes and specifications shall apply: 4.2.1

National/International Standards and Codes AASHTO M182

Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats

AASHTO M307

Standard Specification for Silica Fume Used in Cementitious Mixtures

AASHTO T26

Standard Method of Test for Quality of Water to be Used in Concrete

AASHTO T199

Standard Method of Test for Air Content of Freshly Mixed Concrete by the Chace Indicator

AASHTO T277 (ASTM C1202)

Standard Method of Test for Electrical Indication of Concrete's Ability to Resist Chloride Ion Penetration

ACI117

Specification for Tolerances for Concrete Construction and Materials and Commentary

ACI 211.1

Standard Practice for Selecting Heavyweight, and Mass Concrete

ACI214R

Evaluation of Strength Test Results of Concrete

ACI224R

Control of Cracking in Concrete Structures

ACI225R

Guide to the Selection and Use of Hydraulic Cements

Proportions

for

Normal,

I~OC. NO.

KOC-C-006

II

Il

Page 13 of 75

REV.2

ACI301

Specifications for Structural Concrete

ACI302.'IR

Specification for Structural concrete for Buildings

ACI304R

Guide for Concrete

ACI305R

Guide to Hot Weather Concreting

ACI308R

Guide to Curing Concrete

ACI309R

Guide for Consolidation of Concrete

AC1311.4R

Guide for Concrete Inspection

ACI318M

Building Code Requirements for Structural Concrete and Commentary

ACI347

Guide to Formwork for Concrete

ACI SP 66

ACI Detailing Manual - Details and Detailing of Concrete Reinforcement

ASTM A 82 ASTM A 82M

Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

ASTM A153/ ASTM A 153M

Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A1851 ASTM A185M

Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A307

Standard Specification for Carbon Steel Bolts and Studs, 60000 PSI Tensile Strength

ASTM A496! ASTM A496M

Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement

ASTM A 497! ASTM A497M

Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete

ASTM A 6151 ASTM A 615M

Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A 767 ASTM A 767M

Standard Specification for Zinc Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A 7751 ASTM A 775M

Standard Specification for Epoxy Coated Reinforcing Steel Bars

Measuring,

Mixing,

Transporting,

and

Placing

Page 14 of 15 ASTM C 311 C31M

Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33! ASTM C33M

Standard Specification for Concrete Aggregates

ASTM C39 ASTM C39M

Standard Test Method for Compressive Strength of Cylindrical n,... .. Specimens

ASTM C40

Standard Test Aggregates for

C42 C42M

",t",

Method

for

Organic

Standard Test Method for Obtaining and and Beams of Method for

Impurities

in

Drilled

ASTM

Standard

ASTM C78 ASTM C78M

Standard Method for Flexural Strength Simple Beam with Third-Point Loading)

ASTM C87

Standard Test Method for of Organic Impurities in Aggregate on Strength of Mortar

ASTM C88

Standard Method for Soundness of Aggregates by Sodium Sulfate or Magnesium Sulfate

ASTM ASTM 94M

Standard Specification for Ready-mixed Concrete

ASTM C1091 ASTM C109M

Standard Test Method for Compressive Strength of Hydraulic Mortars (Using or 50 mm Cube Specimens)

ASTM

Standard Cement

14

Moisture in Fine Aggregate Concrete (Using

of

Methods for Chemical Analysis of Hydraulic

ASTM C115

Standard Test Method for Fineness of Portland Cement by the Turbidimeter

ASTM C117

Standard Test Method for Materials Than 200) Sieve in Mineral Aggregates by Washing

ASTM C1

Standard Terminology Relating to Aggregates

ASTM C1

Standard Method for Density, Relative Density (Specific Aggregates Gravity) and Absorption of

ASTM C1

Standard Test Method Density, Relative Density (Specific Aggregates Gravity) and Absorption of

tJm (No.

and Concrete

Page 15 of 75

REV.2

ASTM C131

Standard Test Method for Resistance to Degradation of Small­ Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136

Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138!

ASTM C138M

Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C142

Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C143! ASTM C1431V1

Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150! ASTM C150M

Standard Specification for Portland Cement

ASTM C1511 ASTM C151M

Standard Test Method for Autoclave Expansion of Hydraulic Cement

ASTM C171

Standard Specification for Sheet Materials for Curing Concrete

ASTM C172! ASTM C 172M

Standard Practice for Sampling Freshly Mixed Concrete

ASTM C185

Standard Test Method for Air Content of Hydraulic Cement Mortar

ASTM C186

Standard Test Method for Heat of Hydration of Hydraulic Cement

ASTM C191

Standard Test Methods for Time of Setting of Hydraulic Cement by Vicat Needle

ASTM C192! ASTM C192M

Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C204

Standard Test Methods for Fineness of Hydraulic Cement by Air-Permeability Apparatus

ASTM C215

Standard Test Method for Fundamental Transverse, Longitudinal, and Torsional Resonant Frequencies of Concrete Specimens

ASTM C227

Standard Test Method for Potential Alkali Reactivity of Cement­ Aggregate Combinations (Mortar Bar Method)

Page 16 of 75

DOC. NO. KOC-C

REV.2

I ASTM ASTM C231M

Standard Method for Air Content Concrete by the Pressure Method

ASTM C232 ASTM C232M

Standard

ASTM

Standard Method for by Gillmore

ASTM C289

Standard Method Potential Alkali-Silica Reactivity of Aggregates (Chemical Method)

ASTM C 2931 ASTM C293M

Standard Method for Flexural Strength of Concrete (Using Simple Beam With Center-Point Loading)

ASTM C295

Standard Guide Concrete

ASTM

Standard Specification for Liquid Membrane-Forming Compounds for

ASTM C311

Standard Test Methods Sampling and Natural Use in Portland-Cement

ASTM C4031 ASTM C403M

Standard Method for Time by Penetration Resistance

ASTM C452 ASTM C452M

Standard Test Method for Cement Mortars Exposed

ASTM ASTM C457M

Standard Method for Microscopical Determination of Parameters of the Air-Void System in Hardened Concrete

ASTM C469 ASTM C469M

Standard Test Method for Static Modulus of Poisson's Ratio in Compression

ASTM C4941 ASTM C494M

Standard Specification for Chemical Admixtures for

ASTM C496 ASTM C496M

Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens

ASTM

Standard

2

Freshly Mixed

Methods for Bleeding of Concrete

of Setting of Hydraulic-Cement

Petrographic Examination of Aggregates for

Setting

Ash or

Concrete Mixtures

Expansion of PortlandSulfate

of Concrete in Compression

Method for

ASTM C566

Standard Test Method for Total Aggregate by Drying

ASTM

Standard Method Carbonate Rocks for Method)

Moisture Content of

for Potential Alkali Reactivity of Aggregates (Rock Cylinder

Page 17 of ASTM C618

C642

REV.2

Specification Natural Pozzolan for

Coal Fly Ash in Concrete

or

Standard Test Method for Density, Absorption, and Voids in rnanan Concrete

ASTM C684

Standard Test

ASTM C8031 ASTM C803M

Standard Test Method Concrete

ASTM C805 I ASTM C805M

Concrete

ASTM C827 ASTM C827M

at Standard Test Method for Change in Cylindrical Specimens for Cementitious Mixtures

ASTM C856

Standard Practice for Petrographic Examination of Hardened Concrete

ASTM C876

Standard Reinforcing

for Making, Accelerated Curing, and Test Penetration

of Hardened

Test Method for Rebound Number of Hardened

Ages of

for Corrosion Potentials of Uncoated in

ASTM C900

Standard Concrete

ASTM C920

Standard Specification for Elastomeric Joint Sealants

ASTM C101 ASTM C1012M

Mortars

Method for Pullout Strength of

for Length Change of Hydraulic-Cement

ASTM C 10381 ASTIVI C 1038M

Standard

ASTM C10401 ASTM C1

Standard Methods for In-place Density of Unhardened and Hardened Concrete, Including Roller Compacted concrete In Place by Methods

ASTM C1 I ASTM C1064M

Standard Hydraulic

ASTM C1

Standard Test Method for Portland-Cement Hardened Hydraulic-Cement Concrete

ASTM

1

ASTM C1202

Method for Expansion of Hydraulic in Water

..... T'"',rQrt

of

Mixed

Concrete

Standard Method for Alkali-Carbonate Rock

Content of

Change of Concrete Due to

Standard Method for Indication of Concrete's Ability to Resist Chloride Ion Penetration

Page 18 of

REV.2

Used in Cementitious

ASTM C1240

Standard Mixture

ASTM D751

ASTM D75M

Standard

ASTM D512

Standard

Methods for Chloride Ion in Water

ASTM D516

Standard

Method for Sulphate Ion in Water

Aggregates

ASTM D1751

for Preformed Expansion Joint Filler for and Structural Construction (Non-extruding Bituminous Types)

ASTM D3665

for Random Sampling of Construction

ASTM D3963 1

ASTM D3963M

for Fabrication and Jobsite Handling of Reinforcing Bars

ASTM E11

for Wire Cloth and

ASTM E961 ASTM E96M

Standard

ASTM

Test Methods for Water in Contact with Earth under Walls, or as Ground Cover

ASTM F1554

Standard Specification for Anchor Bolts, ksi Yield Strength

AWS

Methods for Water Vapour

Welding Society - Steel

.1

sieves Technical requirements and testing

sieves of metal wire cloth

Test sieves of perforated metal

1.

812

Aggregates ­ 102: Methods for Sampling

103: Methods for Determination Distribution Sec 103.1: 104: Method for Petrographic Examination Part 105: Methods for Determination Section 105.1: Index Section 1 Index of Aggregate

of

and 105­

Page 19 of Part 117: Method for Determination of Water-Soluble Chloride Salts 123: Method for Determination of Alkali-Silica Reactivity - Concrete Method BS 1881

Methods of Testing (Not Methods of Accelerated Curing of Test Part 11 for New Design) 121: Method of Determination of Modulus of Elasticity in Compression Water Absorption Part 1 Method for Determination Part 1 Methods for Analysis of Hardened Concrete Part 128: Methods for Analysis of Fresh Concrete 131 : Methods for Cement in a (Not for New Design) Part 201: Guide to the Use of Non-Destructive Methods of Test for Hardened Concrete (Not for New Design) Part Recommendations on Use of Electro- magnetic Covermeters in 206: Recommendations for Determination of Part

Recommendations for Assessment of Concrete Strength by Near-to-Surface Tests Part 208: Recommendations for Determination of the Initial Surface Absorption of 209: Recommendations for the Measurement of Dynamic Modulus of Elasticity 3892-2 & 3

BS 4449

Pulverized Fuel Ash Part 2: Specification for 3: Specification of Specification

to be Used as a Type I Addition for Use in Cementitious Grouts

Sulfate-Resisting Portland

Steel for the reinforcement of - Weldable reinforcing steel - Bar, coil and decoiled product - Specification

BS 4482

wire Specification

BS 4483

Steel Fabric for the Reinforcement of Concrete - Specification

4550

5975

Methods of 3: Physical 3: Physical

reinforcement of concrete priducts ­

Strength Section for Heat of Hydration Section 3.8:

Code of Practice for Temporary Works Procedures and the Permissible Stress Design of Falsework

REV.2

Page 20 of 15

8500

- Complementary British Standard to EN 206-1 Part 1: Method Specifying and for the Specifier Part 2: for Constituent and Concrete Scheduling, dimensioning, bending and reinforcement for concrete - Specification

1

cutting

of steel

Methods of cement Part 1: Determination of strength Part analysis of cement Part of setting soundness Part 5: test for pozzolanic cements Part Determination of fineness Part Methods of taking and samples of cement of hydration - Solution method Part 8: Part 9: of hydration method Part 10: Determination of the water soluble chromium (VI) content of cement Part 1: Composition, specification and conformity common cements

197-1

206-1

1: Specification,

Production

Conformity 450-1 &2

451

Fly for concrete Part 1: Definitions, specification Part Conformity evaluation Method testing fly ash 1. Determination of Determination

EN 932 -1

conformity criteria

calcium oxide content by wet sieving

General Properties

Aggregates Part 1: Methods for

Sampling BS EN 934

Admixtures for concrete, mortar and grout Concrete admixtures - Definitions, requirements, conformity, marking and labelling

BS EN 1008

Mixing water for the from processes concrete

BS EN 1097

for mechanical Part 1: Determination Part 6: Determination absorption

specification for sampling, testing, of water including water recovered industry as mixing water for

physical properties aggregates the resistance to wear (micro-Deval) particle and water

REV.2

Page 21 Part 7: Determination Pyknometer Part 8: Determination of

particle

density

of filler

-

polished stone value

BS EN 1367

Tests for thermal and weathering properties of aggregates Part 2: Magnesium Part 4: of drying shrinkage Part 6: Determination of resistance to freezing and thawing in salt

BS EN 1744-1

Tests for chemical properties of aggregates - Part 1: Chemical analysis

EN 1992-3 NA UK National Annex Eurocode 2: Design of concrete structurePart 3 . Liquid retaining and containment structures BS EN 12350

Air Content -

BS EN 12390

~r':'vr,orlon(~OI"i manpower necessary for carrying out

8.2 8.2.1

8.2.2

Broadly normal-weight shall be proportioned in produced for construction by means of controlling several as()ec[s to attain characteristics of concrete, such as higher workability, or setting time (as required), permeability, durability and uniform appearance.

mix

The Contractor shall comply with the following requirements as described in this Standard objectives of producing a sound and high performing reinforced concrete construction.

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9.0

CONCRETE MIX REQUIREMENTS

9.1

Concrete Grades

9.1 .1

Concrete shall be designated by the grades, having the specified cement contents with or without cement replacements for the following applications and conditions as given below:

a.

Aboveground Concrete i) ii) iii)

b.

Belowground Concrete i) ii)

c.

d.

3

Grade A: Minimum 380 kg/m of OPC.

3 3 Grade B: Minimum 342 kg/m of OPC + 38 kg/m of SF.

3 3 Grade C: Minimum 285 kg/m of OPC + 95 kg/m of PFA.

Grade D1: Minimum 380 kg/m 3 of SRPC for all general conditions of exposure 3 Grade D2: Minimum 342 kg/m 3 of SRPC + 38 kg/m of SF for severe condition, when sulphate (S04) is over 1500 ppm in water.

Blinding or Mud mat Concrete i)

Grade E1:

ii)

Grade E2:

121

Sufficient quantities of SRPC for concrete with characteristic 2 strength equal to 1ON/mm or greater (as specified). Sufficient quantities of SRPC for concrete with characteristic 2 strength equal to 15N/mm or greater (as specified).

Concrete Exposed to Saline Water Grade A, Grade B or Grade C shall be specified with the protective coating as per clause 18.0 of this Standard, when concrete is subject to alternate wetting and drying of saline water.

9.1.2

The appropriate quantities of cement and aggregates shall preferably be measured by weight. All measuring equipment used for weigh batching shall be in good serviceable condition and approved by KOC. However, the batching of aggregates by volume shall be allowed with prior permission by KOC. In case of volume batching, the containers shall be of such shape and dimensions that their volume can be easily checked by measurement.

9.2

Design Strengths

9.2.1

The Designer shall specify the required design compressive strengths of concrete for the applicable Grades A to E by the minimum characteristic strengths at 28 days after placing of concrete for a particular application; and the Contractor is responsible to achieve that specified strengths by controlling the process of construction.

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The characteristic strengths (cube strengths) as defined in clause 3.1.4 of this Standard, shall be established by trial mixes, but shall not be less than the minimum values specified in Table 4 below.

Table 4 - Minimum Compressive Strength of Normal-Weight Concrete (fckl Concrete Grades I Strength Classes 2 3 4 5 6

Characteristic Strength for Characteristic Strength for . Cubes at 7 days (N/mm2) . Cubes at 28 days (N/mm2) .

Grade A / C30

21

30

Grade B! C30

21

30

Grade C! C30

21

30

Grade 01 or 02 ! C30

21

30

10

15

10

Grade E1 ! C1 0 Grade E2! C15

9.3

Free Water-Cement Ratio

9.3.1

All concrete mixes other than blinding concrete (Grade E1/E2) shall be made to achieve good workability of concrete with the following water-cement ratio as below:

9.3.2

a.

Maximum 0.40 for foundations , rafts, on-grade I suspended slabs and beams; and

b.

Minimum 0.45 for concrete columns, retaining walls , parapets and other structural members of width less than 250 mm.

If cement replacements (CR) are used, the water-cement ratio shall be the amount of water divided by the total contents of cement and cement replacement. Where admixtures are added to the concrete, its water content shall be accounted in the calculation of water-cement ratio as per BS EN 1097-6.

9.3.3

Water-cement ratio shall be continuously checked at the mixer with due allowance being made for water (if any) contained in the aggregates. Under no circumstances, additional water shall be added between the mixing and the time of concrete placement. Additionally, the Contractor may be asked by KOC to carry out further tests for water-cement ratio on fresh concrete samples taken at the time of placement.

9.4

Slump

9.4.1

Concrete mix shall be made with appropriate quantity of water to achieve workability, consistency and plasticity, so that it has the proper slump for ease of conveying, handling, placing and compacting without segregation.

9.4.2

Generally, the slump shall be within the ranges of 50 mm to 100 mm when no super plasticizers are used at the time of placement and shall be measured in

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accordance with ASTM C143/ASTM C143M or BS EN 12350 Part 2. However, the following slumps in concrete, when conveyed by transit mixers, shall be maintained for the recommended applications as below: Table 5 - Recommended Slumps for Various Types of Construction

~~~,.~,,~~. lr========~D~e~s~cr~ip~t~io~n~========1iM~a~x~im~um~S~lu~m:':p~ISlump Reinforced I Plain Foundations, Footings, Paving and Slabs on grade

75mm

25 mm

2

Columns, Pedestals and Retaining Walls

100 mm

25 mm

3

Beams and Slabs

50mm

25mm

4

Mass Concrete

50mm

25 mm

9.4 .3

The slump of concrete mixes shall be measured by the Contractor's Quality Control Engineer in the presence of KOC.

9.5

Initial Setting Time

9.5.1

Concrete mix for ease of handling shall have the initial setting time not less than one (1) hour between the time it is produced and placed in the form work. Normally with a maximum time not exceeding one (1) hour between mixing and placing, the total time from the mixing to the initial set in the mix shall be minimum two (2) hours, but should not exceed six (6) hours maximum .

9.5.2

However when the concrete workability is also tested from the trial mixes, the initial setting time of concrete comprising the same proportions of CR (if any) with retarding superplasticizer as selected and applied, shall be determined in accordance with BS EN 196-3 or ASTM C191 I ASTM C266 at the maximum temperature in concrete during placement.

9.6

Total Salt Content

9.6.1

Chlorides The total chloride content of concrete from all sources, expressed as chloride ion when tested in accordance with BS EN 196 Part 2, for the sum of both acid soluble and water soluble chlorides, shall not exceed by weight of dry cement including CR as follows: a. 0.30% for OPC b. 0.15% for SRPC

9.6.2

Sulphates The total sulphate content of concrete from all sources, expressed as S03, when tested in accordance with ASTM C1012, shall not exceed 4% by weight of dry cement including CR.

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10.0

CONCRETE TRIAL MIX

10.1

Design Mixes for Structural Concrete

10.1.1

The Contractor shall prepare the design mixes as applicable for structural grades in accordance with BS EN 206-1 and BS 8500 on trial basis, using past reliable test data or field experience to select approximate proportions of the materials to be used in concrete and water-cement ratio.

10.1.2 Several trial batches shall be made by varying the relative amounts of fine and coarse aggregates, cement contents including cement replacement if any or maximum water-cement ratio, aggregates grading as well as desired slump to achieve right kind of workability and design strengths of the specified concrete grades. If dense impermeable concrete is required to resist adequately the ingress of harmful salts, the approved retarding super plasticizer shall be used in the trial

mixes. 10.1.3 Test concrete mixes shall be produced for KOC approval by the Contractor, when the trial mixes have established the proposed workability and the required proportions and quantities of the aggregates per cubic metre (m 3) and super plasticizer (if used) for each grade of concrete, which shall then be tested as follows: a.

Six (6) test mixes shall be prepared separately and six (6) test cubes shall be made from each test mix for each grade of concrete in presence of KOC Representatives. The test cubes shall be made, cured and tested in accordance with BS EN 12390-2.

b.

36 cubes of each grade of concrete shall be tested for crushing strength at 28 days and the mean strength and standard deviation shall be established for each grade.

c.

The test mixes shall be acceptable, when complying with the requirements as below. i) ii) iii)

the mix proportions and workability are meeting this Standard; the standard deviation for each grade is 3.5 N/mm2 or less; and the characteristic strength of each grade to be calculated as 6 N/mm2 below the mean strength is equal to or more than the specified designed strengths.

10.1.4 Normally, the strengths of the structural grades may exceed the specified strengths, but they shall be closely monitored by KOC during the actual production of concrete by employing the proper quality control measures.

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1 1

Design Mixes for Blinding Concrete 1

The trial mix proportions for this concrete left to the discretion of the (3) test shall made separately Contractor. When they are selected, with these proportions and three (3) 150 mm shall prepared from each mix for testing at 28 days. The trial proportions and water-cement ratio shall be approved, jf the average strength of (9) cubes is not less than the specified characteristic strength.

1

The test mix proportions and water-cement ratios once accepted shall not be changed without prior KOe approval. No production tests shall be required for this grade of concrete, however mix proportions and water- cement ratios may be monitored by KOe as

10.3

Absorption Tests

1

1 The hardened concrete as a measure of tests shall be

10.3.2

trial mixes shall be tested for absorption of water ingress of aggressive salts. No absorption

out in

Absorption follows:

with BS 1881 Part 1

as

a.

After the trial (3) 150 mm cubes shall be from each grade of concrete and shall be immersed in water at seven (7) days.

b.

curing period, 75 mm diameter core

taken from for the full 150 mm thickness,

trimmed to approximately mm length.

c.

The

d.

The shall then be cooled in a dry airtight for 24 hours, weighed and immersed immediately in a tank containing water at 20 0 e with the longitudinal axis of the cores horizontal, and with mm depth

e.

left under immersion for 24 hours, then removed, and reweighed.

f.

shall

dried in an oven at 105°e for 72 hours.

absorption shall be calculated as from immersion,

as a percentage of

cores will be of lengths differing from graph given in 1881 Part 1 shall volume.

in mass resulting dry mass. mm, a correction factor from to standardize the

39 of 75 h.

11.0

REV.2

absorption percentages for grade shall be and if than 6 the absorption of the mixes shall acceptable. The mean and the lowest absorption percentages shall each grade shall for comparison purposes with recorded in-situ as absorption when carried out on cores from 16.5.4 of Standard.

FORMWORK

11.1 11.1.1

Formwork shall be wherever necessary to confine the ....,.\.',..,r,OTC and to the dimensions and surface finishes as

11.1.2

Formwork shall sufficient strength to withstand the pressure resulting from concrete, shall sufficient rigidity to placement and vibration of maintain the tolerances specified in clause 11.6 of this Standard.

11.2

Material

11.2.1

Formwork shall constructed of new timber of sound quality without any fissures and cracks or framing and shall be lined with either minimum 12 mm thick new plywood with smooth face or other equal and approved lining material, suitable to obtain a smooth fair face on the

11.2.2

If special finish to the exposed surfaces is specified, plastic coated marine plywood or equal shall be used to achieve required finish.

11

Any particular formwork shall be to such number that quality of the any damages due to specified finish can be maintained; and shall not of vibration during placement and removal of formwork.

it

11.3 11

1

The and material specification of the formwork, as well as construction I erection shall be the responsibility the Contractor, who should take care the relevant safety during work.

11

Formwork shall be designed for all appropriate loads concrete as outlined in BS 5975 or ACI 347; shall lateral arising to plastic flow of concrete like a liquid with a specific gravity up to

11.3.3

Formwork adequately braced wind loads for lateral stability and shall be of sufficient strength within allowable stresses materials to its shape, levels and position without deformation or deflection.

11

Formwork shall be sufficiently tight to prevent of paste or grout shall all wedges to be nailed to prevent slipping or distortion during vibration of

Page 40 of

REV.2

11

Formwork shall any chance

11.4

Preparation of Form Surfaces

11

All surfaces of forms and embedded materials shall thoroughly cleaned off accumulated cement paste or grout from previously cast concrete, and other material new is placed.

1

11.4.2

installed on hard ground or hard surface so that there shall not settlement, concrete is placed and

placing the bars or the concrete, of forms shall be with a KOC approved coating material to effectively absorption of moisture from the as well as to prevent bond with the concrete. material shall be a 'field applied, form oil or sealer or a factory applied nonabsorptive liner, shall be non-staining, non-reactive and rust preventive. on the forms shall be prior to concrete

11

Where finishes are required, coating materials, which will impart a the concrete, shall not be applied to the form

to

11.4.4 Formwork shall constructed in such a way that they can be removed easily without to the concrete. No portion of wood forms shall left in the concrete. 11.4.5 All exposed finished edges of concrete shall chamfered by a cut triangular mm x mm timber unless specific architectural finishes from nominal are and approved by KOC. 11.4.6 Forms shall provided 1 from the horizontal.

the top face of sloping work, where the slope exceeds

11.5

Removal of Forms

11.5.1

Formwork for columns, walls, sides of and parts not supporting the weight of concrete shall be removed as soon as concrete hardened 48 suffiCiently any damage to it from removal operations, but not hours (2 days) placement.

11

Forms and shoring in the formwork for beams, slabs, and other structural members shall remain in place until the concrete has reached 2/3 specified compressive strength at days and when concrete been continuously cured as per clause 15.0 of this Standard.

11.5.3

a guidance minimum recommended that formwork and centering shall in position striking, shall be normally as per 6 below after concrete is placed. However, the actual removal time shall be with the results from the test prevailing weather conditions and appropriate curing methods and time.

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Table 6 - Recommended Duration of Formwork 51. No.

Member Description

Minimum Duration (Days)

Formwork to Columns, Walls & Deep beams (Vertical)

2

11.6

2 7 14 14 21

Formwork to Slab Soffits (Horizontal)

3

Props to Slabs (Vertical)

4 5

Formwork to Beam Soffit (Horizontal) Props to Beams (Vertical)

Tolerances

Tolerances shall be achieved without appreciable changes by the formwork to the hardened concrete as follows: Table 7 - Tolerances for Formed Surfaces II

_. '._. ~I

1.1.

2

12.0

Type of Structure

Tolerance

Buried or unexposed Concrete

± 15mm

Exposed Concrete including Floor Slabs and Paving

±6mm

REINFORCEMENT

12.1

General

12.1.1

Reinforcements to be used in structural concrete comprise of hot or cold rolled , weldable mild steel, round plain and twisted (deformed) bars; and generally shall be uncoated unless otherwise specified. Reinforcing bars in the form of galvanized welded mesh fabrics are also used in some places.

12.1.2

Construction drawings showing all the dimensions and locations of reinforcing bars to be placed in the structures shall be reviewed and approved by KOC prior to fabrication of reinforcements.

12.2

Reinforcing Bars

12.2.1

All main reinforcements shall be high yield deformed bars conforming to Grade designation 460 with a specified characteristic strength of 460 N/mm2 in accordance with BS 4449 or Grade 60 with a specified yield strength 60,000 Ib/in 2 (414 N/mm2) in accordance with ASTM A615/ASTM A615M .

12.2.2

All spirals, stirrups (links) and ties (binders) shall be plain round bars conformin~ to Grade designation 250 with a specified characteristic strength of 250 N/mm in accordance with BS 4449 or Grade 40 with a specified yield strength 40,000 Ib/in 2 (276 N/mm2) in accordance with ASTM A615 IASTM A615M.

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12.2.3

Steel wires for spiral reinforcement shall be cold drawn as per BS 4483 or ASTM A82.

12.2.4

If specified for protection against corrosion as a special case, reinforcing bars shall be epoxy coated in accordance with ASTM A775/A775M and shall comply with the requirements given in NACE SP 0187.

12.3

Welded Wire Fabric

12.3.1

Welded wire mesh fabric shall be fabricated from plain or deformed cold drawn wires of gauge and mesh size as shown in the drawings or as required, and shall conform to BS 4483 or ASTM A185 I ASTM A 496/A496M.

12.3.2

The spacing between welded mesh intersections shall not exceed 300 mm in the principal direction and shall be specified by the designation number as given in BS 4449 or ASTM A185/A185M or ASTM A496/A496M.

12.4

Certification

12.4.1

Test certificates from the approved Manufacturers giving ultimate strengths, elongation and cold bending together with chemical analysis of the reinforcing steel, shall be furnished to KOC for approval of each consignment of reinforcements delivered to the Site.

12.4.2

All materials supplied shall be new, and when delivered, shall be free from rust, mill scale, harmful amounts of deleterious salts or coatings, which may reduce or destroy bond with concrete.

12.5

Shipping and Storage

12.5.1

Reinforcements shall be handled and shipped in a manner so as to avoid any bending, twisting or other damage to the bars. Bars shall be kept in the yard according to the placement schedule as follows: a.

Bars of different sizes shall not be bundled together. However for small jobs, bars may be bundled together; but each group of bars having the same piece mark shall be tagged and coded.

b.

Metal tags as approved by KOC shall be provided and labeled with legible marks. All bundles shall be tagged at each end, and shall be made to the largest size as practical for handling and shipping

c.

Reinforcement shall be stored aboveground on platforms, skids or other supports. Direct contact with the ground / soil shall be avoided and proper drainage shall be provided around the stored material to minimize corrosion.

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12.6

Fabrication

12.6.1

All reinforcing bars shall be cut, bent or formed to the dimensions and configurations as per the bar bending schedules prepared by the Contractor from the approved construction drawings, and shall be within the tolerances specified in BS 8666 or ACI SP 66.

12.6.2

Reinforcing bars shall be bent cold using pin sizes in accordance with BS 8666 or ACI SP 66, but shall not be re-bent or straightened without prior KOC agreement. However, the bending of reinforcing bars at a concrete cold joint shall not be permitted .

12.6.3 Diameter of bend measured on the inside of the reinforcing bars shall not be less than the following : Table 8 - Minimum Diameters of Bend

EJ

Bar Size

Main Bar s - 8 mm to 25 mm

-Minimum Diameter 6x bar diameter

2

Main Bars - 30 mm to 34 mm

8 x bar diameter

3

Stirrups & Ties - 16 mm and smaller

4 x bar diameter

4

Stirrups & Ties - greater than 16 mm

6 x bar diameter

12.6.4

Reinforcing bars having a reduced section, kinks and visible transverse cracks at bends or otherwise damaged shall not be used and shall be removed from the site.

12.6.5

Reinforcing bars shall not be tack or spot-welded for any purpose. Fully welded splice or other welding to reinforcement shall be permitted as an exception by KOC, only after the Contractor's proposed method of welding appropriate to the grade of steel and type of welding rod has been found satisfactory and approved.

12.7

Cover

12.7.1

Minimum concrete cover to reinforcing bars, except for extremely corrosive atmosphere, other severe exposure or fire protection shall comply with construction drawings, but generally shall be not less than the minimum specified in Table 9 of this Standard . In case of likely severe exposure of reinforcing steel bars to potential corrosive environment, the increased covers shall be provided as agreed with KOC .

12.7.2 Cover to reinforcing bars shall be carefully checked before casting of concrete , as insufficient cover can lead to the ingress of chloride in the concrete and cause corrosion to the reinforcements .

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Table 9 - Minimum Concrete Cover

_.

12.8

,_.

Location

Minimum Cover

Concrete in contact with ground I soil and in foundations up to base plate level

75 mm

2

Concrete exposed to saline water

75mm

3

Formed concrete surfaces exposed to weather (exterior), but not in contact with ground I soil

50mm

4

Formed concrete surfaces not exposed to weather (interior) and not in contact with ground I soil

38 mm

I

Placing of Reinforcing Bars

12.8.1 All reinforcing bars shall be accurately placed as per the construction drawings and shall be properly fastened before concrete is placed, and shall be secured in position against any displacement. Ties at intersections shall be made with 1.5 mm diameter annealed wires and the wire ends shall be bent to avoid any protrusion in the cover area . 12.8.2 Lap splices shall be in accordance with bar bending schedules made as per BS 8666 or ACI SP 66. Welded wire fabric shall be lapped 11/2 meshes to each other, and wherever required, shall be extended through construction / contraction joints except in paving and at keyed joints in slabs on grade. 12.8.3 Concrete blocks of proper size shall be provided to support reinforcing bars and maintain the correct cover to concrete as specified in the construction drawings. Concrete spacer blocks and / or metal chairs shall be placed as required to prevent displacement of reinforcing bars during concreting. Spacer blocks shall be made to the same specifications of concrete. 12.8.4 Chairs made of reinforcement shall be used to provide supports to the top mats of

reinforcement in suspended and foundation slabs .

12.9

Tolerances for Placement

Reinforcing bars and embedded items shall be placed within the tolerances as specified in ACI 117 or ACI 301 . Otherwise, they shall be unfastened and shall be fixed again to maintain the specified covers. 12.10

Cleaning of Reinforcement

a. All reinforcing bars before concrete is being placed , shall be cleaned to make them free of mud, grease, paint, oil, loose rust or other materials , that may adversely affect bonding with concrete . b. All cleaning materials such as rags, sandpapers etc. Shall be disposed off as directed by KOC.

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13.0

CONCRETE PRODUCTION

13.1

General

13.1 .1

Concrete of high quality shall be produced by meeting the requirements as specified in the relevant clauses of this Standard and in accordance with ACI 304R or BS 8500 and BS EN 206-1 .

13.1.2

Concrete production shall be carried out in a central batching plant and mixing equipment, approved by KOC that shall conform to ACI 304R. Mixing and the addition of water in the truck mixers shall not be permitted.

13.1.3 The Contractor shall prepare a checklist for concrete production such as that used by the National Ready-Mixed Concrete Association (NRMCA) or equal for KOC approval. 13.2

Batching

13.2.1

The appropriate quantities of Portland cement and each size of aggregates, as approved on the basis of the trial mixes for designated concrete grades shall be measured by means of weigh batching. Water and admixtures for mixing shall preferably be measured by weight than by volume. However for small jobs, concrete by volume batching shall be allowed .

13.2.2 Batching equipment shall be capable of consistently measuring all the quantities within the following tolerances for the each batch smallest or largest as per ACI 301 : a. b. c. d.

Cement: Water: Aggregates: Admixtures:

± 1% ± 1% ±2% ±3%

13.2.3 All weighing / measuring equipment shall be calibrated on a regular basis by the third party inspection; and validity of the test certificates for the calibrated equipment(s) shall be limited for a period of six (6) months only to ensure that the required accuracy is continuously maintained. All weighing / measuring equipment shall be approved by KOC and shall be maintained in serviceable condition. 13.2.4' The moisture content of aggregates shall be determined on daily basis to check any apparent change therein and shall be recorded for adjustment. The weight of aggregates added to mix shall be revised accordingly. The water added to the mix shall similarly be modified to meet the water-cement ratio as per the clause 9.3 of this Standard or as per the concrete trial mix. 13.3

Mixing

13.3.1 All concrete shall be mixed in a batch mixer of KOC approved size and design that shall generally comply with ACI 304R and shall have an accurate water-measuring device.

REV.2

Page 46 of 75 13.3.2

batch mixer shall capable of thoroughly combining the and water into a homogeneous and uniform mass within the specified and discharging the without any harmful segregation. mixer shall bear and the recommended

manufacturer's rating per minute and

indicating the rated capacity be operated accordingly.

1

Mixing shall continue for one batch for minimum mixing time not less than two (2) minutes to get uniform consistency and colour. However, excessive for mixing shall not be

13.3.4

contents of the drum shall be discharged further.

before

13.3.5 Whenever mixing is suspended for 30 min (1/2 hours) or longer, the drum mixer shall thoroughly washed out with water. The operator shall be KOC approved and shall be competent enough to remain in continuous control of the mixer operation, wash water shall disposed off as directed by

13.3,6

No re-tempering of partially concrete shall allowed by adding quantities of water, cement or aggregates. All the Dlelces of partially hardened shall be removed and as instructed by

13.4

Concreting in Hot Weather

13.4.1

Daily temperature shall be obtained by approved source for planning concrete operations.

Contractor from a

No concrete shall be placed when the shade temperature exceed 37.7°C (100°F) at the job Site. In hot weather suitable means shall provided to ensure the of concrete does not (90°F). 13.4.2

not exceed (90°F) at the time any concrete is having a temperature in it shall be rejected by

13.4.3 Before starting the production precautions shall be taken by limit by considering 13.4.4 Normal provisions 1 precautions generally considered as follows: a. b. c. d. e. f.

concrete, adequate normal provisions 1 Contractor to keep

temperature forecast during

inherent

Shading of mixing plant and Shading of aggregates, water tank and cement silo. Replacing mixing water (100%) with flaked ice. heat-reflecting covers. Insulating water tanks and supply piping. white the mixing tanks and

temperature shall

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13.4.5 The ice making plant should be sized to supply 100% of the mixing water requirements as flaked ice. Where ice is to be used to cool the water, care shall be taken to ensure that all ice has melted before the concrete leaves the mixer. In case even ice mixing in concrete is not able to reduce the concrete temperature sufficiently in certain places, nighttime concreting shall be considered essential during extreme hot weather situations. 13.4.6 As an alternative to an ice making plant, the cooling of the aggregates should be considered by liquefied nitrogen cooling system upon KOC approval. 13.4.7 No concreting shall be carried out during heavy sandstorms, heavy rain or heavy fog or when the ambient temperature in the shade exceeds 43°C. 13.5

Dry Mix Concrete

The Contractor may procure dry mix concrete from the Supplier (Batching Plant) and mixing of water shall be done at Site. However, all necessary controls, advice on water admixtures, Site supervision and temperature controls shall be as per this KOC Standard ; and concreting shall be witnessed by the KOC approved QNQC Engineer in accordance with clause 23.0 of this Standard. 14.0

CONVEYING, PLACING AND FINISHING

14.1

Conveying Concrete

14.1 .1

Concrete, after being thoroughly mixed in the mixer and discharged from it, shall be conveyed within the specified time limit to the final place at the job site by agitator trucks which shall prevent segregation, initial hardening or loss of workability.

14.1.2

The agitator drums shall be kept clean at all times and shall be free from any partially or fully hardened concrete prior to loading so that fresh concrete shall not be contaminated.

14.1.3

Drums shall be slowly revolved at the agitating speeds as specified by the Manufacturer to maintain the plasticity of concrete. However, addition of water is prohibited during transit and at the point of discharge. Water tanks shall be completely disconnected from the drums of the agitator trucks.

14.1.4

Concrete shall be unloaded through the use of chutes , spouts, skips or by pumps as acceptable to KOC ; but under no circumstances any aluminium pipe or other conveying equipment containing alurninium shall be allowed to come in contact with fresh concrete, when it is conveyed to the point of placement.

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14.2

Reinforcements and Embedded Items

14.2.1

Prior to placing concrete in the formwork, all the reinforcing bars and embedded items be checked for the required cleanliness and shall be from loose rust, scale and oil that may adversely the bonding capacity concrete.

1

The reinforcing bars and bars (stoppers) if provided shall also examined the proper fixing, positioning and alignment as the construction drawings, which all previously approved by KOC. Concrete cover shall be rechecked for adequacy and other metal bar chairs shall secured in position.

1

Inserts including but not limited conduits, pipes, pipe sleeves, and anchor bolts shall have covers as specified in clause 1 of this Standard. Conduits and pipes shall not be placed than three (3) diameters on centres.

14.2.4

Inserts, which project through be approved by KOC.

1

5

equipment Anchor bolts for rotating equipment should be as specified by Manufacturer. High strength bolts and sleeves shall be provided in accordance with the recommendations by the Manufacturer or by Designer within the tolerances as given in construction drawings.

14.2.6

EN 898 or ASTM A307 or equal. All Anchor bolt material shall conform to anchor bolts shall galvanized in accordance with EN ISO 1461 or ASTM A153.

14.2.7

The Contractor shall take care of adequate time for inspection any corrective actions to be implemented in his planning, when pours are scheduled.

cover, shall

of non-corroding type and shall

mechanical and chemical properties of bolts and nuts 898 or ASTM A307.

1

conform to

14.3

1

1

14.3.2

Joints in concrete be located as as practicable at so harmful liquids including saline from any source can not collect or pond over them. Watertight joints shall conform to clause 21 of this Standard. Construction Joints a.

No deviation be permitted without KOC agreement where construction joints are specifically called in the construction

b.

Additional construction joints due to limitation of shuttering or concreting shall kept to a minimum and their locations be decided as agreed by KOC.

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d. Stop ends for vertical joints shall be removed as soon as practicable without any damage to the concrete face . The surface shall be roughened to remove all laitance, without disturbing the coarse aggregate by pressure jetting with air and water or by wire brushing. Care shall be taken to ensure that the jOint is clean prior to placing fresh concrete . The new concrete shall be well worked against the old face to ensure good joint. e. The use of expanded metal or other perforated material as a stop-end is not acceptable . f.

Care shall be exercised not to break the concrete-steel bond at any time .

14.3.3 Expansion and Contraction Joints Expansion and contraction joints shall be designed and constructed in accordance with ACI 224R & ACI 318M . Details and positioning of these joints, together with the materials to be used , shall be indicated on the construction drawings. Reinforcement shall not be extended across the joints, and the cover to the reinforcing bars at the side of joints shall be as specified . Joints shall be properly constructed , as the failure of any joint sealants would allow chlorides to attack the rei nforcements. 14.3.4

Expansion joints shall be formed by using 20mm thick filler strip and 20mm deep KOC approved sealant suitable for environment. Filler and sealant shall be in accordance with ASTM 01751 and ASTM C920 respectively or similar.

14.4

Placing Concrete

14.4.1 Concrete shall be placed continuously as near as possible to its final position and shall be in layers of such thickness that no concrete will be deposited on partially hardened concrete which will form planes of weakness within the section If a section cannot be built continuously, construction joints shall be located at sections as shown in the drawings or where acceptable to KOC . 14.4.2 Concrete shall neither be dumped in separate piles and then leveled and worked together; nor shall the concrete be deposited in large piles and then moved horizontally into final position. However, concrete shall generally be placed in accordance with ACI 301 or ACI 304R, unless otherwise specified. 14.4.3 Concrete shall not be dropped freely into its place from a height more than one (1) metre to avoid segregation except in any special case approved by KOC. Concrete shall be placed through spouts or flexible drop chutes, where dense reinforcing bars may cause segregation of the coarse aggregates. 14.4.4 Concrete shall be deposited in sequence as shown on the construction drawings and within 1-112 metre of its final position in regular courses of thickness not exceeding 600 mm so that the formwork or reinforcing bars or any embedded items shall not be displaced.

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of placement shall be maintained as

14.4.5

temperature of concrete at the clause 13.4 of this Standard.

14.4.6

The work shall properly planned and organized in shall be compacted in final position within two introducing cement into the aggregates.

14.4.7

Placing structural concrete against excavation shall not be allowed, as the concrete coating materials could not applied afterwards on

14.4.8

Before placing new concrete over hardened concrete, the surfaces shall properly cleaned, moist and treated with KOC approved proprietary bonding agent in accordance with the manufacturer's instructions.

a manner that concrete hours from the time of

14.5 1

1

All concrete shall consolidated by vibration, spading, rodding or forking so that the concrete is thoroughly compacted around the reinforcing bars, embedded items, and into corners of forms, eliminating entrapped air, honeycombs and stone pockets within the

1

Full compaction shall achieved by KOC approved methods throughout the successive layers shall entire depth of the concrete so that all completely bonded together.

14.5.3

Unless otherwise specified, power driven poker or pan type vibrators of approved type shall be for compaction. shall be inserted vertically at distances or applied in such a manner as to ensure that the approximately 500 mm concrete is satisfactorily and uniformly compacted.

14.5.4

Immersion vibrators shall penetrate through the full depth of the layer, and when is of concrete, shall enter and re-vibrate that to underlying ensure that the successive layers are fully bonded.

14.5.5

vibration shall not be allowed so as to avoid surface laitance, segregation and leakage through formwork or damages the embedded formwork.

14.5.6

Immersion vibrators shall be withdrawn slowly to prevent the formation of voids, and shall not be used to move concrete horizontally along the forms, which may cause segregation.

14.5.7

External vibrators shall not used without obtaining KOC approval for type and variety of the vibrators, as well as for the suitability of formwork design.

14.5.8

No than one (1) vibrator shall concrete placing operations.

kept available on the job

during all

Page

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REV.2

14.6 14.6.1

When freshly mixed concrete is to be placed in contact with recently hardened concrete, the surface of joints shall be properly prepared to secure a high quality bond and watertightness.

14.6.2

The hardened concrete shall be thoroughly roughened and cleaned of all dry mortars, deposits, dust, grease, oil or other foreign materials by stiff wire brushing, chipping hammers, scarifiers, sandblasting or any other mechanical equipment to expose sound concrete with some coarse particles.

1

The hardened concrete construction joints, and of joints between footings and columns I walls, between columns I walls and or floors they support, joints in unexposed walls etc. shall be dampened (but not saturated) with concrete. immediately prior to placing

14.6.4

The hardened of horizontal construction joints in exposed work, and jOints in the middle of beams, girders, jOists, and slabs shall be dampened (but not saturated) and then thoroughly covered with a coat of grout shall grout of similar proportions to mortar in the concrete. be at least 10 mm thick and attaining its initial set, the fresh concrete shall be deposited.

14.6.5

contain liquids shall also meet the above The joints in structures designed this procedure in addition to the reqUirements described in clause 21.2 Standard.

14.1

Finishing Concrete Surfaces

14.7.1

Generally after forms are removed, the concrete surfaces shall be cleaned off from all bulges, fins and small projections by chipping or tooling. Any cavities shall be and honeycombed areas shall repaired. Stains shall be removed to a surface in uniform colour. However, the surfaces of following finishes, as described in

1

may specified with one of the specification or drawings:

a.

Rough form finish for all concrete surfaces not exposed to view.

b.

Smooth form finish for all concrete

Rough

exposed to

Finish

Rough form finish surfaces shall be reasonably true to and plane with no nQr"T''''' requirements for selected facing materials. Holes and minor defects shall be patched; otherwise shall left with the texture imparted by the forms. This finish shall produced as class F1 for against which backfill, rendering or further concrete will be placed. Appearance is not important, but

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where backfill shall be placed against the concrete, the surface finish shall be made smooth to apply coating over it as a continuous protective membrane . 14.7.3

Smooth Form Finish Smooth form finish surfaces shall be produced with a hard, uniform texture on the concrete by using the suitable form facing material such as plywood tempered hardboard, metal, plastic, paper or other acceptable material capable of providing the desired result. Smooth form finishes shall be distinguished with the following classes F2 or F3 as below: a.

Class F2 finish shall be provided for surfaces that are permanently exposed to view, but where highest standard of finish is not required.

Joints between panels shall be horizontal or vertical unless otherwise specified . The finish shall be such that no general filling or surface pitting are required, but fins, surface discolouration or other minor defects shall be remedied by approved methods to KOC satisfaction. The cast surfaces wherever necessary, shall be coated to protect it from ingress of chlorides, but in any case ledges shall not be allowed at the position of joints in the formwork where they can collect salts after being washed down by dew or rainwater or from saline water. b. Class F3 finish shall be provided for surfaces that are permanently exposed to view, but here good appearance and alignment are of special architectural importance . To achieve this class of finish , the formwork shall be made by the Contractor with the large sheets of applicable facing materials. The sheets shall be arranged in a uniform pattern approved by KOC . Joints between sheets wherever possible, shall be made to coincide with architectural features, sills, window heads or changes in direction of the surface. All joints between panels shall be vertical or horizontal unless specified otherwise. Suitable joints shall be arranged and fitted so that no blemish or mark is imparted to the finished surfaces. 14.7.4

Unformed Finish Unformed finishes shall be distinguished with one of the following classes U1 to U4 as below: a. Class U1 finish is for surfaces of roads, subsequent stages of construction, bonded concrete topping or cement mortar bed to receive paving . The concrete shall be uniformly levelled and tamped. Proper surface treatment shall be required at the time of topping application. b. Class U2 finish is broom finish for ramps and side walks.

of75 c.

Class U3 finish shall floated finish for surfaces of beds to receive mastic paving, paving bedded in mastic, and for exposed surfaces, , smooth, trowelled surface is not . When the concrete sufficiently, this finish shall wood floated to give a uniform from tamping marks.

d.

Class U4 finish hard, smooth, steel trowelled finish tops of buried foundations (to later), surfaces of paving, tops of walls, coping and other exposed to weathering. It to surfaces of beds and thin, flexible sheet and adhesives. finish shall steel trowelled by hand or a dense, smooth, uniform surface free from trowel

14.8 1

1 The Contractor shall adopt a systemic pour card for concrete placement to record all information and data to ensure the quality control of the job as follows: a.

concrete placement shall show the pour description, time, date, concrete finishes, estimated delivery, special or equipment required elephant trunks, pumps,

b.

A checklist section shall provide for truck access, grade, crane access to forms, adequacy of formwork including strength, cleanliness, finishes and for and placement of reinforcing bars, anchor bolts and other embedded items or block-outs.

c.

A placement test section shall indicate individual load delivery time, batch slump, cubes taken and actual quantity delivered.

d.

e.

load indicating as a minimum, a trip ticket shall accompany of this Standard. pour card concrete placement and shall be retained for

batch shall be approved by

15.0 15.1 15.1.1 Curing is one of the most important factors in the production of good and durable concrete by maintaining a satisfactory level of moisture temperature in concrete during

period, immediately following of concrete.

replacement (PFAlSF) is to some percentages, in producing superior quality of impermeable concrete compared concrete alone; and the converse is true for inadequate curing.

· NO. KOC-C-006 15.1

Page

Freshly laid concrete shall protected from premature drying and excessively hot or cold temperatures, and mechanical injury, and shall maintained with minimal loss of moisture at a relatively constant temperature, for the time period required to cement and proper hardening of the concrete. complete hydration of

15.1.3 If I is as pozzolan, the shading of concrete from the direct be considered necessary, sunlight during placement or placing in the evening as concrete very little bleeding and is to early shrinkage cracking, particularly during the period of hardening in the summer months (May to September).

15.2

Curing Methods

15.2.1

Curing shall start immediately as after concrete is placed ·finished. Concrete surfaces shall be continuously moist for 24 hours of temperature within prevent loss of water due to evaporation and rapid concrete as per the following procedures: a.

Ponding or continuous sprinkling.

b.

Absorptive mat or fabric kept continuously

c.

Continuous mist spray.

d.

Waterproof paper material for curing

e.

Application of curing compounds as

as

ASTM C171.

ASTM C309.

1

Contractor shall employ one the above KOC approved methods and shall ensure by regular frequent inspection that concrete is properly cured by duration of curing. adequate wetting in the remaining period of the concrete shall tested for permeability to establish that curing has been correctly carried out.

15.3

Duration of Curing

1

1

1 Curing shall be continued for at least 7 days in case of all concrete except high early strength for which the period shall be minimum 3 days. mass concrete, it shall be minimum 10 days otherwise specified. When PFA or SF is used as cement replacement the for the concrete production, curing shall continue for at least 14 days for all concrete grades.

1

15.4.1 Metal forms heated by the sun and all wooden forms in contact with the concrete shall be kept wet to minimize moisture loss until they can be safely removed. After shall cured until the of the period as removal of forms the specified in clause 1 above of this Standard.

Page

REV.2

1

Horizontal surfaces shall with a compound after the concrete is placed and shall then be bunded and 1I00JUt::U with water or draped with wet hessian together with a perforated pipe, covered with white impervious sheeting held firmly in

1

Vertical timber formwork shall be with wet hessian as soon as the concrete is placed. Vertical surfaces shall with a curing compound formwork is removed, draped with wet hessian, covered with white impervious sheeting held firmly in place along all and kept continuously wet for curing period. Care shall be taken to avoid faster drying by moving winds through the formwork. 2

15.4.4 Hessian shall be as per AASHTO M1 weighing at least 0.29 kg/m . Impervious sheeting shall be 1000 g polyethylene, and shall be lapped not less than 150 mm

edges and ends. 15.5

Curing Compound

15.5.1

The curing concrete above curing compound

white and shall be water based wax emulsion for will be subsequently coated. Otherwise the with coating.

15.5.2 Liquid membrane curing compounds shall be applied as recommended by the

Manufacturer and shall not used on any surface to bonded, unless it is proven that other material is to not prevent bonding.

additional or curing compound shall

15.5.3 Curing compound shall

approved by KOC and shall approved supplier with the confirmation that the curing compound shall requirements.

15.6

During the curing period, the concrete shall be from damaging mechanical particularly load stresses, heavy shock, and