SAES-Q-001 - Criteria for Design and Construction of Concrete Structure.pdf

Engineering Standard SAES-Q-001 7 January 2016 Criteria for Design and Construction of Concrete Structures Document Responsibility: Civil Standards Committee

Contents

Previous Issue: 2 July 2014

1

Scope............................................................. 2

2

Conflicts and Deviations................................ 2

3

References..................................................... 2

4

General Requirements................................... 6

5

Quality Control……........................................ 6

6

Concrete Materials…..................................... 7

7

Design and Execution.................................... 8

8

Marine and Coastal Concrete Structures..... 22

Next Planned Update: 7 January 2019 Page 1 of 24

Contact: Abduljabbar, Sami Abdulaziz (abdusa0x) on +966-13-8809680 Copyright©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

1

Scope This Standard covers the minimum mandatory requirements governing the design, specifications, and construction of all onshore structural, offshore structural and non-structural concrete.

2

3

1.1

This standard does not cover the design, Manufacturing, specification, casting, and erection of precast and prestressed concrete products. Refer to SAES-Q-012 for Precast and Prestressed Concrete Structures.

1.2

This Standard does not cover concrete for fire proofing applications. Refer to SAES-B-006 for additional information on the use of concrete as fireproofing material.

1.3

This standard states the minimum requirements that need to be fulfilled for offshore and marine concrete.

1.4

Special concrete mixes such as self-consolidated concrete (SCC), roller compacted concrete, previous concrete, heavy weight concrete, light weight concrete, concrete used for radioactive shielding applications, etc., shall be reviewed and approved by CSD / Civil Engineering Group.

Conflicts and Deviations 2.1

Any conflicts between this Standard and other applicable Saudi Aramco Engineering Standards (SAESs), Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the company or buyer representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this Standard in writing to the company or buyer representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

References The following reference documents shall be considered an integral part of this standard except otherwise noted. Use the edition in effect on the date of the publication of this standard unless otherwise noted. 3.1

Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement Page 2 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

Saudi Aramco Engineering Standards SAES-A-113

Geotechnical Engineering Requirements

SAES-A-114

Excavation and Backfill

SAES-B-006

Fireproofing for Plants

SAES-B-055

Plant Layout

SAES-H-001

Coating Selection and Application Requirements for Industrial Plants and Equipment

SAES-H-003

Protective Coatings for Industrial Concrete Structures

SAES-H-004

Protective Coating Selection and Application Requirements for Offshore Structures and Facilities

SAES-L-440

Anchor for Buried Pipelines

SAES-M-001

Structural Design Criteria for Non Buildings Structures

SAES-M-100

Saudi Aramco Building Code

SAES-P-104

Wiring Methods and Materials

SAES-Q-005

Concrete Foundations

SAES-Q-006

Asphalt and Sulfur Extended Asphalt Concrete Paving

SAES-Q-007

Foundations and Supporting Structure for Heavy Machinery

SAES-Q-009

Concrete Retaining Walls

SAES-Q-012

Criteria for Design and Construction of Precast and Prestressed Concrete Structures

SAES-T-911

Telecommunications Conduit System Design

SAES-X-800

Cathodic Protection for Existing Reinforced Concrete Structures

Saudi Aramco Materials System Specifications 09-SAMSS-075

Caulking Compound (Joint Sealant)

09-SAMSS-097

Ready-Mixed Concrete

09-SAMSS-106

Epoxy Coating of Steel Reinforcing Bars

12-SAMSS-007

Fabrication of Structural and Miscellanies Steel Page 3 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

Saudi Aramco Engineering Reports SAER-5803

Concrete Repair Manual

SAER-6610

In-Ground Sulfur Pit Design, Assessment and Repair - State-of-the-Art Strategies

Saudi Aramco Standard Drawing AA-036602

Concrete Masonry

Saudi Aramco Construction Safety Manual 3.2

Industry Codes and Standards American Concrete Institute All ACI standards and recommended practices including but not limited to the following list: ACI 117

Standard Specifications for Tolerances for Concrete Construction and Materials

ACI 224.3R

Joints in Concrete Construction

ACI 301-10

Specifications for Structural Concrete

ACI 302.1R

Guide for Concrete Floor and Slab Construction

ACI 304R

Guide for Measuring, Mixing, Transporting and Placing Concrete

ACI 305R

Hot Weather Concreting

ACI 318

Building Code Requirements for Structural Concrete

ACI 350

Code Requirements for Environmental Engineering Concrete Structures and Commentary

ACI 350.1

Specification for Tightness Testing of Environmental Engineering Concrete Containment Structures

ACI 350.4R

Design Considerations for Environmental Engineering Concrete Structures

ACI 350.5

Specifications for Environmental Concrete Structures

ACI 357.3R

Guide for Design and Construction of Waterfront and Coastal Concrete Marine Structures

ACI 360R

Design of Slab on Ground

ACI 440.1R

Guide for the Design and Construction of Concrete Reinforced with FRP Bars Page 4 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

ACI 440.5 ACI 530/ ASCE 5/TMS 402

Specification for Construction with FiberReinforced Polymer Reinforcing Bars Building Code Requirements for Masonry Structures

ACI 562

Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings

ACI SP-66

Detailing Manual - Details and Detailing of Concrete Reinforcement

ASTM International ASTM A123/123M

Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A615/A615M

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

ASTM A767/767M

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

ASTM A775/A775M

Specification for Epoxy-Coated Reinforcing Bars

ASTM A884/A884M

Specification for Epoxy-Coated Steel Wire and Welded Wire Fabric for Reinforcement

ASTM A1064/A1064M Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, For Concrete ASTM C39/C39M

Test Methods for Compressive Strength of Cylindrical Concrete Specimens

ASTM C55

Specification for Concrete Building Brick

ASTM C90

Specification for Load Bearing Concrete Masonry Units

ASTM C129

Specification for Non-Load Bearing Concrete Masonry Units

ASTM C309

Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C979/C979M

Specification for Pigments for Integrally Colored Concrete

ASTM C1240

Standard Specification for Silica Fume Used in Cementitious Mixtures

ASTM C1580

Test Method for Water-Soluble Sulfate in Soil Page 5 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

ASTM D1751

Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction

ASTM D1752

Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM E1745

Standard Specification for Plastic Water Vapor Retarders Used in Contact with Soil or Granular Fill under Concrete Slabs

Concrete Reinforcing Steel Institute (CRSI) Manual of Standard Practice American Association of State Highway and Transportation Organization

4

AASHTO T291

Standard Method of Test for Determining Water Soluble Chloride Ion Content in Soil

AASHTO

LRFD Bridge Design Specifications

General Requirements Concrete construction shall be in accordance with all requirements of ACI 301-10, except as modified or supplemented in this standard or by contract documents Any placement of concrete designated in the contract documents as mass concrete or any placement of structural concrete with a minimum dimension equal to or greater than 900 mm should be considered mass concrete unless otherwise specified in contract documents and shall comply with ACI 301-10, Section 8.

5

4.1

Construction of concrete hydraulic (liquid-retaining) structures shall comply with ACI 350.5.

4.2

Cast-in-place structural concrete reinforced with fiber-reinforced polymer (FRP) bars shall comply with ACI 440.5 “Specification for Construction with FiberReinforced Polymer Reinforcing Bars”.

4.3

Concrete that is not covered by this document shall comply with the applicable ACI document.

Quality Control The contractor shall employ an independent Saudi Aramco approved testing agency to perform field and laboratory testing which shall include compressive strength tests of Page 6 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

molded concrete cylinders, test for slump, unit weight, air content (where airentrainment is required) and fresh concrete temperature. All testing shall be in accordance with 09-SAMSS-097, “Ready-Mix Concrete.” 6

Concrete Materials The concrete materials shall be in accordance with 09-SAMSS-097, “Ready-Mixed Concrete” and as follows: 6.1

Reinforcement 6.1.1

Reinforcing bars shall be deformed billet steel in accordance with ASTM A615/A615M, Grade 60. Commentary Note: When used as ductile steel elements to resist earthquake effects, deformed reinforcing bar shall be limited to ASTM A706 Grade 60, or ASTM A615 Grades 40 and 60 satisfying the requirements of ACI 318.

6.1.2

Coated reinforcements shall be Fusion Bonded Epoxy in accordance with 09-SAMSS-106.

6.1.3

Welded wire reinforcement shall be plain wire in accordance with ASTM A1064/A1064M.

6.1.4

Galvanized welded wire fabric shall conform to ASTM A767/A767M and shall be acceptable reinforcement in lieu of epoxy coated welded wire fabric coated in accordance to ASTM A884/A884M.

6.1.5

Tie wire shall be black annealed wire, 16 gage (1.29 mm) minimum. Fasten epoxy-coated reinforcement with tie wires coated with epoxy.

6.1.6

Manufacturing, fabrication, handling, placement and storage of reinforcement shall be in accordance with ACI 318. Commentary Note: Care should be taken to avoid any damage to the coated rebars during shipment, handling, fabrication and placement of the coated rebars. The extent of the damage and repair of the coating shall be in accordance with 09-SAMSS-106.

6.2

Masonry Units Details and dimensions of the concrete masonry units shall be as shown on Standard Drawing AA-036602. Manufacturing and testing shall be in accordance with the following specifications for each type of masonry unit to be Page 7 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

supplied under the Purchase Order. Actual finish dimensions for each type of masonry shall be as specified in the Purchase Order. 6.2.1

Hollow and solid load-bearing concrete masonry units shall be manufactured and tested according to ASTM C90.

6.2.2

Hollow and solid non-load bearing concrete masonry units shall be manufactured and tested according to ASTM C129. Commentary Note: Masonry units manufactured to ASTM C129 are intended for use as nonload bearing partitions. They should not be used for exterior walls unless a moisture-protective coating is used.

6.2.3 6.3

6.4

Concrete building brick shall be Grade N, manufactured and tested according to ASTM C55.

Joints 6.3.1

Joint filler strips for expansion joints shall conform to ASTM D1751 or ASTM D1752. Type shall be as noted on the design drawings

6.3.2

Joints sealant materials shall conform to 09-SAMSS-075.

Accessories Accessories shall meet the requirements of ACI 301-10.

7

Design and Execution 7.1

SAES-B-055, “Plant Layout,” shall be used for minimum horizontal and vertical spacing or clearance requirements of concrete structures.

7.2

SAES-L-440, “Anchor for Buried Pipelines,” shall be used for the design of anchor blocks.

7.3

SAES-M-001, “Structural Design Criteria for Non-Building Structures,” Section 4.2, Loading Requirements, shall be used for minimum design load requirements on non-building concrete structures.

7.4

SAES-M-100, “Saudi Aramco Building Code,” shall be used for the design of concrete buildings.

7.5

SAES-M-009, “Design Criteria for Blast Resistant Buildings” shall be used for the design of blast resistant buildings.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

7.6

SAES-Q-005, “Concrete Foundations,” shall be used to establish minimum design requirements for concrete foundations, except foundations and supports for heavy machinery.

7.7

SAES-Q-007, “Foundations and Supporting structures for Heavy Machinery,” shall be used to establish minimum design requirements for concrete foundations and elevated supports for heavy machinery.

7.8

SAES-Q-009, “Concrete Retaining Walls,” shall be used to establish minimum design requirements for concrete retaining walls.

7.9

ACI 318, “Building Code Requirements for Structural Concrete,” shall be used for the design of concrete structures.

7.10

ACI 350, “Code Requirements for Environmental Engineering Concrete Structures,” shall be used for the design of conventionally reinforced environmental engineering concrete structures. Commentary Note: Liquid retaining structures should be leak tested while their walls are exposed (Refer to ACI 350.1).

7.11

ACI 530/ASCE 5/TMS 402 shall be used for the design of masonry structures.

7.12

AASHTO, “LRFD Bridge Design Specifications,” shall be used for the structural design of reinforced concrete bridges, culverts, and pipeline crossing. Unless otherwise specified, the design shall be based on HS20 truck. Maintenance and construction crane loads shall also be considered.

7.13

Concrete paving shall be in accordance with the following: a)

Areas subject to spills, wash water, fire water and sidewalk shall be paved with a minimum thickness of 100 mm of reinforced concrete with minimum reinforcements of 150 x 150 MW9 x MW9 welded wire fabric. Areas subject to vehicular traffic shall be in accordance with paragraph b). Commentary Note: 150x150 MW9xMW9: 150 mm is the spacing between the reinforcement and MW9 (9 mm²) is the cross sectional area of the rebar.

b)

Paving slabs subject to vehicular traffic shall be a minimum thickness of 150 mm of reinforced concrete. The design load shall be as specified in paragraph 0 of this standard. The design of the paving shall be based on ACI 360R. Minimum reinforcement shall be 150x150 MW18.7 x MW18.7 welded wire fabric or equivalent.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

c)

Concrete paving slope to the catch basins or trenches shall not be less than 1:65 (1.5%). The maximum drop to catch basins from high point of paving shall be 200 mm. Commentary Note: Ensure that slope will not jeopardize the movement of traffic.

d)

Where foundations protrude through the paving, 12 mm diameter reinforcing bars, 800 mm long, shall be placed diagonally in the paving at all interior corners.

7.14

ACI 440.1R, “Guide for the Design and Construction of Concrete Reinforced with FRP Bars,” shall be used for the design when Glass Fiber Reinforced Plastic Bars (GFRP) are specified.

7.15

Concrete shall be either structural or nonstructural, as follows:

7.16

a)

Structural Concrete: All reinforced concrete including concrete with minimum reinforcement for temperature and shrinkage control. The minimum 28-day design compressive strength (ASTM C39) shall be in accordance with Table 2. Water retaining structures, shall have a minimum 28-day design compressive strength of 35 MPa (5000 psi).

b)

Non-Structural Concrete: Unreinforced concrete of no significant structural value such as lean concrete for sub-slabs. The minimum 28 day design compressive strength (ASTM C39) shall be 14 MPa (2000 psi).

Exposures Structural concrete members shall be assigned an exposure class in accordance with the severity of the anticipated exposure of members in Tables 1.A, 1.B and 1.C. Table 1.A - Sulfate Exposures Classes

Exposure Class

Water-soluble Sulfate (SO4) in Soil, Percent by Mass1

Dissolved Sulfate (SO4) in Water, ppm2

S0

SO4 < 0.1

SO4 < 150

S1

0.10 ≤ SO4 < 0.20

150 ≤ SO4 < 1500

S2

0.2 ≤ SO4 < 2.00

1500 ≤ SO4 < 10,000

S3

SO4 > 2.0

SO4 ≥ 10,000

S4 1 2

Sulfur Pits

Percent sulfate by mass in soil shall be determined in accordance with ASTM C1580. Concentration of dissolved sulfates in water in ppm shall be determined by ASTM D516 or ASTM D4130

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

Table 1.B - Water Exposures Classes Exposure Class

Exposure Environment Concrete dry in service

W0

Concrete in contact with water and low permeability is not required Concrete in contact with water and low permeability is required

W1

Exposure Class

Table 1.C - Chloride Exposure Classes Below Ground Exposure3 Water Soluble Chloride (cl-) in Soil, % by Weight4

Water Soluble Chloride (cl-) in Ground Water, ppm5

Above Ground Exposure

Environmental and Marine Exposure

 Non-coastal (more than 5 km from the coastline) C0

Up to 0.1

Up to 2000

 Concrete dry or protected from moisture by damp-proof membrane  Members fully enclosed within buildings  Coastal (up to 5 km from the coastline, but excluding members classified under other exposures)

C16

0.1 to 0.5

2,000 to 10,000

More than 0.5

More than 10,000

C27 Concrete in contact with Sabkha10

 Concrete permanently submerged in sea water  Concrete subjected to cyclic wet and dry from water other than seawater (e.g., structures subjected to intermittent brackish wash water)  Coastal (up to 5 km from the coastline, but excluding members classified under other exposures)  Concrete in tidal8, and splash9 zones in marine environment

Based on the exposure classes assigned from Table 1.A, B and C, concrete mixtures and steel reinforcement type shall comply with the most restrictive requirements in Table 2.

3

Water soluble chloride in ground water need to be identified if water table is less than one meter below the bottom of the foundation or structural element 4 Water-soluble chloride ion in soil shall be determined in accordance with AASHTO T291 5 ppm; parts per million measured after soil is compacted. 6 Sewage Treatment Plant is classified as C1 exposure. 7 Water Cooling towers is classified as C2 exposure. 8 Tidal zone – as mentioned in ACI 357.3R-14. 9 Splash zone – as defined in SAES-H-004. 10 Sabkha - as defined in SAES-A-114.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

Table 2 - Requirements for Reinforced Concrete by Exposures Class Exposure

Max. w/cm

Min. f’c (MPa)

Cement Type

Reinforcing Steel

S0

0.45

20

No restriction

Uncoated

S1

0.40

28

II or V

Uncoated

S2

0.40

32

V

Uncoated Uncoated

S3

0.40

32

V + Pozzolan or Slag11, 12

S4

0.36

60

V+Slag

Uncoated

W0

0.45

20

No restriction

Uncoated

W1

0.40

28

No restriction

Uncoated

Additional Provisions

Refer to Section 7.17

Max. water-soluble chloride ion (Cl-) in concrete, % by weight of cement13 C0 C1

0.45 0.40

20

I

Uncoated

1.00

32

I + Pozzolan or Slag

ECR14

0.15

Additional Provisions

Refer to Section 8 for environmental concrete C2

0.36

42

I + Pozzolan or Slag

ECR

0.15

Concrete in sabkah shall be protected by appropriate means such as tanking

Commentary Notes: The use of slag or pozzolans including Silica Fume or any combination of the above are limited to structural concrete members only. Plant paving, sidewalks, erosion protection paving and slabs reinforced with welded wire fabric are exempted from the use of Pozzolan or slag. Silica Fume shall be tested prior to use on monthly basis or when changing the source of the materials to confirm its compliance to ASTM C1240. Table 1. Underground exposure category is based on performance of geotechnical investigation as required by SAES-A-113 or availability of prior reports showing soil chemical composition. 11

Pozzolan can be silica fume, fly ash, or natural pozzolan The amount of the specific source of the pozzolan or slag cement to be used shall be at least the amount that has been determined by service record to improve sulfate resistance when used in concrete containing Type V cement. Alternatively, the amount of the specific source of the pozzolan or slag cement to be used shall be at least the amount tested in accordance with ASTM C1012 and meeting the criteria in ACI-318-14, section 26.4.2.2(c). 13 Water-soluble chloride ion content that is contributed from the ingredients including water, aggregates, cementitious materials, and admixtures shall be determined on the concrete mixture by ASTM C1218 at age between 28 and 42 days. 14 ECR – Epoxy Coated Rebars 12

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures Testing of soil shall be for the natural soil and the capillary rise phenomenon shall be considered if the soil is imported.

7.17

Sulfur Pits The following guidelines shall be followed in the construction, repair and replacement of sulfur pits:

7.17.1

ACI 350.2, “Concrete Structures for Containment of Hazardous Materials,” shall be used for the design of sulfur pits.

7.17.2

Design, assessment and repair of sulfur pits shall follow the guidelines and procedures of SAER-6610 “In-Ground Sulfur Pit Design, Assessment and Repair - State-of-the-Art Strategies.”

7.17.3

Pipe rack or heavy structures shall not be supported on the roof, or walls of the sulfur pits.

7.17.4

Minimum concrete cover in sulfur pits shall not be less than 75 mm.

7.17.5

High performance self-consolidating concrete with 65% Ground Granulated Blast Furnace Slag (GGBFS) and 5% silica fume in addition to 30% Type I to produce cement high chemical resistant shall be used for sulfur pit construction or repair. High performance concrete shall meet the following durability criteria:

7.17.6

a.

Minimum compressive strength shall be 60 MPa as measured in accordance with ASTM C39;

b.

Corrected 30 minute absorption of not greater than 1.2%, as measured by BS 1881: Part 122:1983. The absorption test is to be conducted by an independent testing authority on cores taken from cubes or cylinders (or from cast specimens where permitted by the Principal's Representative), from the trial mixes which shall be conducted prior to the commencement of the supply of concrete;

c.

Chloride permeability test shall be carried out in accordance with ASTM C1202 or AASHTO T277. The total charged passed shall not exceed 1000 coulombs.

For existing sulfur pits that are not built with high performance concrete described in paragraph 7.17.5 above, use internal durability lining system of potassium silicate concrete of 50 mm minimum in thickness or a 200 mm thick of high performance concrete as in paragraph 7.17.5, the durability liner shall satisfy the following:

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

a.

Vertical installations shall be anchored to the substrate with “T”type stainless steel anchors at a maximum distance of 300 mm centerlines in addition to steel mesh to mechanically secure the Potassium Silicate to concrete substrate. Concrete shall be treated using chemical resistant high temperature membrane such as urethane-asphalt compound system or equivalent prior to installation of Potassium Silicate.

b.

For slab on grade, castable Potassium Silicate of at least 50 mm thick shall be installed. “T”- type stainless steel anchors shall be used at a maximum distance of 400 mm centerlines in addition to steel mesh to mechanically secure the Potassium silicate to concrete substrate. Concrete shall be treated using chemical resistant high temperature membrane such as urethane-asphalt compound system or equivalent prior to installation of Potassium Silicate.

c.

Potassium silicate and chemical resistant high temperature membranes shall be applied as per manufacturer data sheets.

d.

Durability liner made of high performance concrete shall be anchored to the existing concrete wall by appropriate anchors at a maximum distance of 400 mm centerlines grid pattern in addition to 102 x 102 MW25.7 / MW25.7 providing lap length of 2 full squares as detailed in SAER-6610.

7.17.7

Use Epoxy Novolac Corrosion Resistant Epoxy Render to protect roof soffit.

7.17.8

Waterproofing membrane shall be installed on the external surfaces of sulfur pits that are in contact with soil. Pre-applied HDPE and self-adhesive HDPE sheets shall be used.

7.17.9

All joints shall be filled with chemical resistant high temperature membrane such as urethane-asphalt.

7.17.10 A proper drainage system (e.g., French drain) shall be installed on the external side of the sulfur pits to drain water table. 7.17.11 Waterstops for sulfur pit shall be made of 16 gauge stainless steel plate material as detailed in SAER-6610. 7.17.12 Roof slab may be constructed of precast concrete.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

7.17.13 The design of sulfur pits including concrete mix design, lining system, water proofing and drainage system shall be approved by the Group Leader, Civil Engineering Group, Consulting Services Department. 7.18

Reinforcement 7.18.1

Reinforcement placing drawings and bending schedules shall be prepared in accordance with ACI SP-66 and CRSI Manual of Standard Practice.

7.18.2

Reinforcement placing drawings and bending schedules shall show number, grade, size, length, mark, location, and bending diagrams for reinforcing bars.

7.18.3

Splices in reinforcement shall be detailed, fabricated, and located only as shown on the design drawings.

7.18.4

Fabrication drawings shall indicate the related PO number, release number, and design drawing number.

7.18.5

Reinforcement shall be tagged with weather-resistant metal tags.

7.18.6

Each bundle of fabricated bars shall be tagged. The tags shall indicate reinforcement placing drawing number, release number, mark number, grade, bar quantity, and bar size.

7.18.7

Each bundle of stock-length straight bars shall be tagged to indicate bar quantity, grade, bar size, and bar length.

7.18.8

Fabrication tolerance shall conform to ACI 117.

7.18.9

Table 3 defines the minimum concrete cover measured from outer most rebar (tie bar), that shall be provided for reinforcement of cast-inplace concrete structures.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

Table 3 - Minimum Concrete Cover Concrete Structure Concrete cast against or permanently exposed to earth (including foundations over a sub-slab) Formed concrete exposed to earth or weather:

a.

b.

Supporting Process Equipment such as concrete pedestal for pipe rack support, pipe sleepers, or supports for horizontal vessels Buildings, walkway platforms, stairs, AC pads Concrete not exposed to weather or in contact with ground (which can be inspected from all sides):

c.

7.19

Minimum Cover (mm) 75

75 50

Beams, columns

50

Slabs, walls, joists

25

d.

Concrete exposed to sea water, raw water or sewage

75

e.

Between reinforcement and anchor flange/pipe within pipeline anchor blocks

100

f.

Concrete slab over 50 mm sub-slab

50

g.

Sidewalks, walkways, etc.

50

h.

Sulfur Pits

75

Formwork 7.19.1

The design and construction of the formwork shall be in accordance with ACI 347, Saudi Aramco Construction Safety Manual, and shall be the responsibility of the contractor.

7.19.2

Unless otherwise specified in the contract documents 20-millimeter (¾-inch) chamfer strips shall be provided at all corners on permanently exposed surfaces.

7.19.3

Form-release agents shall not be applied if concrete surfaces shall receive special finishes (e.g., Architectural Finishes) or where the agent may affect applied coverings. Alternately, inside surfaces of untreated formwork shall be soaked with clean water and kept moist before placing concrete.

7.19.4

Form removal shall be in accordance with ACI 301-10 and the following: a)

For structures for which forms do not provide vertical support (e.g., footings, piers, columns, walls, or sides of beams), the forms

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

may be removed 24 hours after completion of placement if concrete is sufficiently hard to prevent damage by form removal, and if curing starts immediately.

7.20

b)

Unless otherwise specified in the contract documents, forms for self-supporting members may be removed if concrete compressive strength is at least 80% of the specified 28-day compressive strength. Refer to ACI 301-10, Section 2.3.4, for determining compressive strength of concrete for removal of formwork.

c)

Unless otherwise approved by the purchaser, forms shall not be left permanently in place.

7.19.5

Unless specified otherwise in the contract documents, formed concrete surfaces shall be constructed in accordance with the tolerances shown in ACI 117.

7.19.6

Formwork for column and wall shall be provided with adequate cleanout openings to permit inspection and easy cleaning after reinforcement has been placed.

7.19.7

All side and bottom surfaces of structures that will be exposed shall be formed.

Joints 7.20.1

ACI 224.3R, “Joints in Concrete Construction,” shall be used to design, construct, and maintain joints and identify sealant materials and jointing techniques.

7.20.2

Isolation joints shall be placed where pavement adjoins vertical surfaces (e.g., walls, columns, catch basins, manholes, and equipment foundations). Isolation joints shall be located in accordance with contract documents.

7.20.3

Dowels at expansion joints shall be properly aligned to prevent any restraint on expansion movement at the joint.

7.20.4

The surface of joints shall be cleaned of scale and laitance and thoroughly wetted, but free of standing water, before placing adjoining concrete.

7.20.5

Concrete paving shall have control or construction joints located at a maximum spacing of 6 meters on centers in both directions.

7.20.6

Expansion joints shall be used in paving adjacent to all poured in place Page 17 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

concrete members.

7.21

7.20.7

Paving or slab construction joints not specified on the drawings shall be located at column centerlines and intermediate intervals.

7.20.8

Waterstops shall be provided in joints where watertight construction is required in accordance with Chapter 5 of ACI 350.4R. Waterstop type shall be specified and shown on the drawings and shall satisfy the function and operation of the structure and shall be installed as per the manufacturer’s recommendations.

Concrete Repair 7.21.1

Evaluation, repair, rehabilitation, and strengthening of reinforced concrete structures should follow ACI 562 “Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings” and SAER-5803, “Concrete Repair Manual.”

7.21.2

SAES-X-800, “Cathodic Protection for Existing Reinforced Concrete Structures,” should be used if Cathodic Protection is considered for the repair of existing deteriorated concrete structures.

7.21.3

Repair of Surface Defects a)

Tie holes, honeycombs, and other concrete surface defects shall be repaired promptly after form removal at a time and in a manner that shall not delay, interfere with, or impair the proper curing of the fresh concrete unless otherwise specified or permitted by Saudi Aramco.

b)

Saudi Aramco shall be notified before proceeding with repair if the defect is any of the following: 1. Depth is greater than 75 mm at the maximum point and surface area is greater than (100,000 mm²). 2. Depth is greater than ¼ the thickness of the member and greater than 150 mm in any other direction. 3. Reinforcing steel is exposed.

c)

Prepackaged grouts and patching compounds or a patching mortar similar to the concrete mix without coarse aggregate may be used with approval from Saudi Aramco.

d)

Out-of-tolerance slabs shall be repaired by grinding down high points and/or raising low points by using an approved self-leveling compound or repair topping if the areas are exposed. Page 18 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

e)

7.22

7.23

Critical slab areas, identified in the contract documents shall be replaced if out-of-tolerance. A demolition and replacement plan for the slab areas shall be submitted to Saudi Aramco for review and approval before proceeding.

Embedded Items 7.22.1

All sleeves, inserts, anchor bolts, waterstops and other embedded items shall be installed in accordance with the design drawings and supported against displacement. Welding of these items to the reinforcing bars shall not be permitted.

7.22.2

The design and installation of anchor bolts shall be in accordance to SAES-Q-005 and the materials selection of anchor bolts shall be in accordance to 12-SAMSS-007.

7.22.3

Projecting steel items (such as grating angles, slide plates, unistrut, steel plates, etc.) which are attached to the formwork and cast at the concrete surface shall be hot dip galvanized in accordance with ASTM A123/A123M or coated with the zinc rich epoxy primer in APCS-1C of SAES-H-001. Additionally, the steel attachment, which anchors these items to the concrete, shall be similarly galvanized or coated.

7.22.4

Reinforcing steel bars, anchor bolts or other steel embedments shall not be connected to the electrical grounding system. Connection of the structure reinforcing or imbedded steel to the lighting protection system shall be as required by SAES-P-111.

7.22.5

Conduits, pipes and other items made from aluminum shall not be embedded in structural concrete unless effectively coated to prevent aluminum-concrete reaction.

Placing Concrete 7.23.1

Concrete shall be placed in accordance with ACI 301-10, ACI 304R and this standard. For Hot Weather Concreting requirements, see Section 7.27.

7.23.2

Equipment made of aluminum alloys shall not be used for pump lines, tremies, or chutes used to discharge concrete from a truck mixer.

7.23.3

Concrete shall not be placed prior to a recorded pre-placement inspection and authorization to proceed by Saudi Aramco.

7.23.4

Raking shall not be used for movement of concrete after placement. Page 19 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

7.23.5

Vibrators shall not be used to move concrete inside forms.

7.23.6

Re-tempering after concrete is mixed shall not be permitted.

7.23.7

Deposit concrete continuously and as near as practical to the final position.

7.23.8

Placed concrete shall be consolidated by mechanical vibrating equipment according to ACI 301-10, Section 5.3.2.5.

7.23.9

Concrete shall be placed on a clean surface. Standing water shall be removed prior to placement of concrete.

7.23.10 Placement of mass concrete shall comply with ACI 301-10, Section 8. 7.23.11 Slabs shall be placed in alternating panels. 7.13.12 The interval between concrete deliveries shall be such that no more than 20 minutes interruption elapse during placement of a single foundation or slab, unless approved by Saudi Aramco. 7.24

Finishing 7.24.1 The finishing of concrete shall be in accordance with ACI 301-10, and ACI 302.1R unless otherwise specified in the construction drawings or job specification. 7.24.2 Equipment bases shall be finished with a floated finish. Stairs, steps, ramps, and walks shall be finished with a broom finish.

7.25

Curing 7.25.1 Structural concrete shall be cured in accordance with recommendations of ACI 301-10 unless otherwise specified. 7.25.2 Maximum total dissolved solids in water used for curing shall not exceed 1000 parts per million. 7.25.3 Water curing shall be continuous until the compressive strength has reached 70% of the specified strength, but not less than 7 days. 7.25.4 The saturated burlaps shall be covered with a plasticized sheet vapor barrier, minimum 0.15 mm (6 mils) in thickness and shall be kept in contact with the concrete surface at all times. 7.25.5 Curing Compound shall be in accordance with ASTM C309 or equivalent. Vendors shall supply datasheet including third party test reports. Page 20 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

7.25.6 Any structure designated as a hydraulic structure in the contract documents shall comply with the following: 1)

Hydraulic structures shall be cured by a wet-cure procedure only (e.g., use of ponding, sprinkling, or a moisture-retaining fabric).

2)

Moist wood forms in contact with concrete shall not be considered as curing for hydraulic structures.

3)

Curing shall occur for a minimum of 14 days.

4)

Wall forms shall be loosened and water continually sprinkled between the wall and forms.

7.25.7 Liquid membrane curing compounds shall not be used on surfaces that shall receive bonded treatments, tiles, paint or other adhered finishes, epoxy toppings, or additional concrete unless otherwise specified in contract documents. 7.25.8 Curing and protection of mass concrete shall be in accordance with ACI 301-10, Section 8.3.1. 7.26

Coating and Protection 7.26.1 A plasticized sheet vapor barrier in accordance with ASTM E1745, Class A, minimum of 0.25 mm (10 mils) in thickness, shall be placed beneath slabs on grade. Outdoor sidewalks are exempted from this requirement. 7.26.2 A 50 mm sub-slab (lean concrete) shall be placed beneath concrete foundations. 7.26.3 A plasticized sheet vapor barrier in accordance with ASTM E1745, Class A, minimum of 0.25 mm (10 mils) in thickness shall be placed below and around the sides of concrete that is placed directly into excavation without the use of formwork, where coal tar or bitumen coating cannot be applied. 7.26.4 All concrete surfaces in direct contact with earth shall be coated with two coats of coal tar or bitumen coating that conforms to APCS-3 or APCS-10 of SAES-H-001. Commentary Notes: APCS-10 shall not be used where soil is contaminated with hydrocarbons and compatibility test shall be conducted when concrete surface is cured with acrylic based curing compound. APCS-3 compatibility test shall be conducted when concrete surface is

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures cured with bitumen based curing compound. Non-structural concrete such as lean concrete or thrust anchor blocks without reinforcement does not require coating.

7.27

Hot Weather Concreting When hot weather conditions exist, the provisions of ACI 305R shall be met. Commentary Note: Hot weather concrete can be defined as job-site conditions that accelerate the rate of moisture loss or rate of cement hydration of freshly mixed concrete, including an ambient temperature of 27°C or higher, and an evaporation rate that exceeds 1 kg/m2/h.

7.28

Concrete for Underground Ducts 7.28.1 Concrete for underground duct envelopes shall be colored in accordance with SAES-T-911 and SAES-P-104 for communication and electrical ducts respectively. 7.28.2 Coloring admixtures shall be in accordance with ASTM C979/C979M. Concrete envelopes for underground ducts and cover slabs for directburied cables can be colored by adding 6 kilograms of coloring oxide powder per cubic meter of concrete unless otherwise specified in contract documents.

8

Marine and Coastal Concrete Structures 8.1

A full environmental Evaluation for offshore and marine concrete structures shall be performed. The evaluation shall include identification of marine organisms including rock boring mollusks and sponges that would pose a threat to the concrete structure and its integrity. Specific susceptibility of the concrete structure to attack by boring organisms in the Arabian Gulf has been associated with the use of calcareous aggregates (where the main constituent of the aggregate is CaCo3) in the concrete. Commentary Notes: Marine structure – any facility that is in contact with sea water. Offshore concrete structure – fixed reinforced concrete, for service in deeper waters far from the shoreline.

8.2

No offshore or marine concrete structure shall be contracted for construction, fabrication or installation (in a marine environment) without the following provisions being satisfied: 1. All marine design parameters shall be specified. Page 22 of 24

Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

2. All special concreting provisions for fabrication and installation shall be specified. The proposed concrete materials and/or protection means shall be supported with literature and case studies. The extent and resistance of the protection means shall be based on full evaluation of the local environmental conditions. 3. The environmental evaluation, marine design specification and concrete specification shall be presented for review and approval to the Manager, Consulting Services Department. 4. The concrete shall contain an approved High Range Water Reducing admixture such that the free water/cement ratio shall not exceed 0.36 and the concrete will be of adequate workability for placement. 8.3

The concrete shall contain an approved High Range Water Reducing admixture such that the free water/cement ratio shall not exceed 0.36 and the concrete will be of adequate workability for placement.

8.4

The concrete shall contain an effective Hydrophobic Pore –blocking Ingredient (HPI) system, used strictly in accordance with manufacturers' instructions and providing a hydrophobic cement matrix throughout, as well as dispersed polymer particles suitable for use as a pore-blocking agent; acceptance criteria are as follows: 8.4.1

The HPI system shall produce concrete conforming with all specified requirements and shall be shown to produce concrete with a corrected 30 minute absorption of not greater than 1 % (one percent), as measured by BS 1881: Part 122:1983, except that the age at test shall be strictly 7 days. The absorption test is to be conducted by an independent testing authority on cores taken from cubes or cylinders (or from cast specimens where permitted by Saudi Aramco), from the trial mixes which shall be conducted prior to the commencement of the supply of concrete.

8.4.2

Chloride permeability test shall be carried out in accordance with ASTM C1202 or AASHTO T277. The total charged passed shall not exceed 1000 coulombs. Commentary Notes: When HPI concrete is used, the following provisions apply: a. Liners and coatings are not required. b. No epoxy coated rebars are required. Uncoated steel rebars are adequate. c.

Backfilling can commence immediately after curing and concrete compressive strength achieve 70% of required strength.

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Document Responsibility: Civil Standards Committee SAES-Q-001 Issue Date: 7 January 2016 Next Planned Update: 7 January 2019 Criteria for Design and Construction of Concrete Structures

7 January 2016

Revision Summary Major revision to align it with the latest edition of ACI 301 and ACI 318. It includes new criteria that will improve the quality of the overall concrete construction, and improve the cost.

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