SAEP-1152 - Approval Procedure for Ready-Mixed Concrete Mix Design

Engineering Procedure SAEP-1152

2 August 2009

Approval Procedure for Ready-Mixed Concrete Mix Design Inspection Engineering Standards Committee Members Kakpovbia, Anthony Eyankwiere, Chairman Rajeh, Saleh Rashid, Vice Chairman Albarillo, Rodolfo Celino Anazy, Khalid Juma Boult, David Carrera, R L Ghamdi, Khalid Salem Ingram, James Young Keen, Peter David Khunaizi, Mohammad Redhi Langla, Edward Charles Mc Ghee, Patrick Timothy Mohsen, Hassan Abdallah Seyed Mohamed, Abdul Cader Shammary, Hamed Abdulwahab Stockenberger, Hans J Suwaidan, Khalid Ali

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5 6 7 8

Scope............................................................. 2 Purpose.......................................................... 2 Conflicts and Deviations................................. 2 References..................................................... 2 New Mix Design............................................. 3 Mix Design with Established Mix ID Number........................................ 4 Submitting, Reviewing and Approving Process.......................... 4 Vendor/Contractor's Responsibility................ 6

Appendix A – Request for Approval (RFA) Concrete Mix Design.............................. 7

Previous Issue: 1 July 2008 Next Planned Update: 1 July 2013 Revised paragraphs are indicated in the right margin Primary contact: Albarillo, Rodolfo Celino on 966-3-3794009 Copyright©Saudi Aramco 2009. All rights reserved.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Table of Contents (Cont'd) Appendix B – Concrete Mix Design Data Sheet... 8 Appendix C – Ready Mix Concrete Trial Batch Report................................... 9 Appendix D – Concrete Mix Design Approval Process Flow Chart............... 10

1

2

Scope 1.1

This Saudi Aramco Engineering Procedure (SAEP) describes the approval process of ready-mixed concrete mix design. It covers only structural and nonstructural concrete mixes described in 09-SAMSS-097 and SAES-Q-001. Special concrete mix design such as those intended for offshore/marine or high temperature facilities are not covered by this procedure.

1.2

This SAEP is intended to establish a standardized methodology of approving ready-mixed concrete mix design to avoid redundancy of reviewing previously accepted mixes by assigning a unique identification number for every mix design approved.

1.3

This procedure does not cover the placement, consolidation, curing or protection of the concrete after delivery to the Purchaser.

Purpose The purpose of this procedure is to shorten and improve the mix design review process and to minimize re-submitting large amounts of test reports and calculations to support a previously-approved concrete mix design.

3

Conflicts and Deviations Conflicts between this Engineering Procedure and any other Saudi Aramco Standards shall be resolved in writing by the company or buyer representative through the Division Head, Projects Inspection Division, Inspection Department of Saudi Aramco, Dhahran.

4

References Unless stated otherwise, all codes and standards referenced shall be the latest issue (including Revisions and Addenda). When industry codes and standards, or Saudi Aramco standards are required for use by project specification they shall become a part of this Engineering Procedure. Page 2 of 10

Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

4.1

Saudi Aramco References Saudi Aramco Engineering Standard SAES-Q-001

Criteria for Design and Construction of Concrete Structures

Saudi Aramco Materials System Specifications

4.2

09-SAMSS-088

Aggregates for Concrete

09-SAMSS-097

Ready-Mixed Portland Cement Concrete

Industry Codes and Standards American Concrete Institute American Society of Testing and Materials

5

New Mix Design 5.1

A new concrete mix design shall be submitted to Saudi Aramco Inspection Department/Batch Plants & Civil Testing Group (BP&CTG) for approval at least 30 working days prior to start of concrete work, using Appendices A, B & C of this standard. Mix proportioning shall be in accordance with the applicable American Concrete Institute Guide.

5.2

A new mix design is required when a proposed mix has no established record indicating that it meets all the requirements of applicable standards or specifications. It is also required if there is a change in type, source or quantity of the constituent parts of a previously approved mix design.

5.3

New mix design shall be supported by successful full-scale plant trials performed and certified by a Saudi Aramco-approved independent testing laboratory. The supplier shall notify the BP&CTG in writing at least 7 working days prior to conducting a plant trial. Witnessing a plant trial is at the sole option of BP&CTG who reserves the right to monitor any or all phases of work required to prepare concrete mix design.

5.4

All quality tests on raw materials shall be performed by a Saudi Aramco approved independent laboratory. Blending and proportioning data including test records by the independent testing laboratory shall be made available upon Saudi Aramco's request.

5.5

The approved mix design shall be assigned a unique Mix Identification (ID) Number, which shall be indicated in Appendix B, "Concrete Mix Design Data Page 3 of 10

Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Sheet". An approved mix design ID number that has become void or obsolete due to change of ingredient or any other reason shall not be re-used. 5.6

In remote sites where the concrete batch plant and the concrete mix designs are approved on one-time basis for a specific project and contractor, new review and approval are required for other Contractors. Commentary Note: One time basis approval is normally granted with certain special conditions, e.g., Quality Control & Quality Assurance commitment from the Contractor. If a new Contractor intends to utilize a batch plant or mix design previously approved with conditions, the Contractor shall be aware of those conditions and is willing to implement such conditions.

6

Mix Design with Established Mix ID Number 6.1

While request for mix design approval for new mixes requires several attachments such as test reports, calculations and mill certificates, mix design with established Mix ID Number require only the Request for Approval (Appendix A) and a copy of the approved Appendix B "Concrete Mix Design Data Sheet". However, the concrete mix design with an established Mix ID Number, needs to be verified if the tests on the constituent parts are not up-todate. If raw materials test reports are not updated based on the frequency set forth in 09-SAMSS-088, the mix design will not be accepted. Commentary Note: Ready mix batch plants are required to perform periodic tests on their concrete constituent parts in accordance with 09-SAMSS-088 and 09-SAMSS-097. Test reports shall be regularly submitted to the Area Projects Inspection Units (APIU). APIU furnishes the BP&CTG of the test results for their review and consolidation. If a batch plant is not periodically submitting the required tests (performed by a Saudi Aramco-approved independent testing laboratory), to the Inspection Department, the proposed mix design will be returned without approval, even if it has an established Mix ID Number.

6.2

7

Mix design with established Mix ID Number shall be submitted for approval for a specific project to the relevant Area Projects Inspection Units (APIU) or the Area Operations Inspection Unit (AOIU) as applicable, at least 3 working days prior to start of work.

Submitting, Reviewing and Approving Process 7.1

Upon the completion of a successful trial batch (plant trial), the supplier is required to fill out the Concrete Mix Design Data Sheets (Appendix B & C) of

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

this procedure and submit it to the BP&CTG for approval. The concrete supplier shall maintain the original records of approved mix designs. 7.2

The construction contractor completes Appendix A and submits to PMT or ME along with forms Appendix B & C. The construction contractor shall ensure that the proposed pre-approved mix design meets the Exposure Criteria of SAES-Q-001 Table 1.

7.3

Saudi Aramco Project Engineer or the Operations Maintenance Engineer verifies that Appendix A, B & C as submitted by the construction contractor meet the project requirements.

7.4

The Request for Approval form (Appendix A) shall be submitted to the Area Projects Inspection Unit (APIU) or to the Area Operations Inspection Unit (AOIU) in their area of coverage, for approval. Copies of the pre-approved mix design (Appendix B & C) and soil and water analysis report in support of the Exposure Type per SAES-Q-001 shall be attached. Commentary Note: In lieu of the soil/water analysis results, project exposure criteria as established in the project's geotechnical/soil's investigation report is acceptable.

7.5

The Area Projects Inspection Unit (APIU) or the Area Operations Inspection Unit (AOIU) is required to: a)

Verify the status of the submitted mix design prior to approval.

b)

Verify if the test reports of the constituent parts of the subject mix design are up-to-date.

c)

Verify if the concrete exposure type (SAES-Q-001, Table 1) of the proposed mix design corresponds with the project's exposure type. The project's exposure type is based on the Soils/Geotechnical investigation report, and shall be submitted with the review request to verify compliance to the exposure requirements of SAES-Q-001 Table 1. Commentary Notes: Inspection Department is monitoring all of Saudi Aramco approved concrete batch plants kingdom wide and updates their status on a monthly basis. The Batch Plants & Civil Testing Group maintains a list of all approved batch plants and mix designs. All mix designs shall be available at the work site office for review at any time by the authorized Saudi Aramco Inspector.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

d) 8

Refer to the Flow Chart of the approval process in Appendix D.

Vendor/Contractor's Responsibility Approval of the concrete mix design shall not be construed as authority for deviation from listed specifications or requirements of the relevant codes and standards and shall not relieve the contractor/vendor from correcting any deviations at his own expense.

1 July 2008 2 August 2009

Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with no other changes. Editorial revision to change document responsibility and primary contact.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Appendix A – Request for Approval (RFA) Concrete Mix Design

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Appendix B – Concrete Mix Design Data Sheet

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Appendix C – Ready Mix Concrete Trial Batch Report

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1152 Issue Date: 2 August 2009 Next Planned Update: 1 July 2013 Approval Procedure for Ready-Mixed Concrete Mix Design

Appendix D – Concrete Mix Design Approval Process Flow Chart

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