Procedure for Form work, Steel bar fixing, Concreting and Cube testing

Procedure for Form work, Steel bar fixing, Concreting and Cube testing

1.0	PURPOSE
	1.1		The purpose of this procedure is to meet the minimum requirements or concreting as per the contract documents for the Project
2.0	SCOPE
	2.1		The scope of this procedure is to meet the minimum requirements for concreting including formwork, steel bar fixing and testing of concrete as per scope of work mentioned in contract documents.
4.0	REFERENCES
	4.1			Approved for construction Drawings (Civil)
	4.2			PIP STS 03001- Plain & reinforced concrete
	4.3			PIP CVS02100 – Site preparation, Excavation & backfill specification.
	4.4			GI-0002.100 – Work permit system
5.0	ABBREVIATIONS
	5.6				NCR	-	Non Conformance Report
	5.7				ITP	-	Inspection and Test Plan
	5.8				DO	-	Director of Operations
	5.9				PD	-	Project Director
	5.10				PM	-	Project Manager
	5.11				QR	-	Quality Representative ( QA/QC Manager-Project )
	5.12				QA	-	Quality Assurance
	5.13				QC	-	Quality Control
	5.15				AFC	-	Approved for Construction
	5.16				QAM	-	QA Manager (Division) / QA/QC Manager (Corporate)
	5.17				CM	-	Construction Manager
	5.18				DE	-	Discipline Engineer
	5.19				PIP	-	Process Industry Practices
	5.20				MSL	-	Mean Sea Level
6.0	PROCEDURE
	6.1				Materials
	6.1.1				All materials like pre-cast foundations rebar, welded wire fabric, welded items such as sleeves, inserts, anchor Bolts, water stops shall be inspected on receipt at site as per the approved shop drawings materials test certificates shall be submitted for review and approval of the Company during the material receiving inspection.
	6.1.2				Materials shall be stored properly by the use of suitable lifting arrangements and care shall be taken to prevent damages to material.
	6.1.3				Materials traceability shall be maintained during receipt, storage and issue of materials as per procedure material management system and site store activities.
	6.1.4				Concrete materials shall be in accordance with of 09-SAMSS-097 ready mixed Portland cement concrete and minimum compressive strength 27.6 MPa (4000 Psi) for 28 days.
	6.1.5				Coated reinforcements shall be fusion bonded epoxy in accordance with 09-SAMSS-106. Handling and fabrication of epoxy coated reinforcement shall be in accordance to ASTM A775 Appendix.
	6.1.6				Reinforcing steel bars shall conform to SASO SSA2, hot rolled, high tensile deformed steel.
	6.1.7				Anchor bolts shall be in accordance to 12-SAMSS-007.
	6.1.8				Steel items such as grating angles slid plates, steel plates etc. shall be hot dip galvanized in accordance with ASTM A123
	6.1.9				Manufactures material test certificate with ultimate strength, elongation             cold bending, chemical analysis of steel shall be submitted to the Company for each consignment of reinforcing steel delivered to the site.
	6.1.10				Reinforcing steel shall be handled and shipped to avoid bending and other damages to the bar.
	6.1.11				The water used in concrete mortar & curing shall be clean & potable it shall be free from suspended material organic matter and other impurities which may adversely affect the concrete.
	6.1.12				Reinforcement shall be neatly stacked on a timber with a good clearance from the ground.
	6.1.13				The concrete mix design shall meet the requirements of the contract specification and drawing.
	6.1.14				The ready mix concrete the following checks shall be carried out upon the arrival of the transit mixer
					a. The delivery ticket with date, time, Quantity and specified strength of concrete.
					b. The vehicle flow meter
					c. The container motor is rotating at constant speed.
					d. The conveying chutes are fit for the purpose.
	6.2				Blinding
	6.2.1				Blinding concrete shall be placed only after the approval of the Company           for the excavation & compaction test as per KE-039227 clause 6.4 & 6.8
	6.3				Installation of pre-cast Items
	6.3.1				A 50 mm lean concrete shall be placed on the bottom of the excavation before placing pre-cast foundations. The pre cast foundation shall be set in place prior to hardening of the lean concrete.
	6.3.2				A layer of clean sand not more than 50 mm thick shall be placed in the bottom of the excavation. If clean sand is used it must be carefully leveled prior to placement of pre-cast foundation and 0.15 mm plasticized sheet vapor barrier shall be beneath the foundation.
	6.3.3				Pre-cast foundation shall be installed with suitable capacity lorry crane as per the approved drawing.
	6.3.4				Necessary adjustments if required are made by the surveyor after placing of the pre cast foundation.
	6.3.5				Prior to start of the back filling all the inspection activities shall be completed and approved by the Company. Concrete surfaces in direct contact with earth shall be coated with 2 coats of coal tar.
	6.4				Rebar Fixing
	6.4.1				Reinforcement bar shall be accurately placed as per approved drawings and should be secured and held in position.
	6.4.2				Ties at intersections shall be made with 1.5 mm dia annealed wire and the end of the wire shall be bent so that they do not protrude in to the cover zone.
	6.4.3				Adequate concrete cover as per AFC drawings shall be maintained while placing reinforcement according to table 2 SAES-Q-001.
	6.5				Formwork
	6.5.1				Formwork for concrete shall be designed to meet the requirement of structure and the required surface finish of the concrete.
	6.5.2				Form work should be sufficient in strength and stability to maintain its positions and shape under levels associated at the time of placing of concrete.
	6.5.3				Concrete cover to the reinforcement shall be as per SAES-Q-001 table # 2 minimum concrete cover clause-5 materials.
	6.5.4				Concrete shall not be placed unless positioning, fixing condition of the reinforcement cleanliness alignment have been checked & approved by the Company.
	6.5.5				The design of construction & formwork shall be in accordance with ACI 347 R
	6.6				Concreting|
	6.6.1				All the concreting works shall conform to the requirements of ACI 318 building code requirements for structural concrete latest edition.
	6.6.2				The concrete foundations shall be placed on areas compacted to at least 95%  of modified proctor density.
	6.6.3				Slump and Cylinder test samples shall be taken from the discharge point in the presence of the Company representative-slump min 75mm  temperature not more than 320C
	6.6.4				Maximum water cement ratio shall be 0.40
	6.6.5				Prior inspection (recorded) is mandatory before placing any concrete.
	6.6.6				Raking shall not be used to move concrete after placement.
	6.6.7				Vibrators shall not be used to move concrete inside forms.
	6.6.8				Concrete shall not be dropped freely where reinforcing will cause segregation       nor to be dropped freely from more than 1 meter.
	6.6.9				Concrete shall be deposited as near as possible to avoid segregation
	6.6.10				Placed concrete shall be consolidated using compatible vibrating equipment supplemented by hand spading, rodding or toughing.
	6.6.11				Concrete shall be placed on a clean surface. Standing water shall be removed prior to placement of concrete.
	6.6.12				Every precaution shall be taken to prevent foreign materials from being introduced in the concrete from any source.
	6.6.13				Concrete placed in the forms shall be to the full depth of the forms and thoroughly worked against the formwork and around reinforcement and successfully layer shall be thoroughly bonded air bubbles formed during mixing and casting shall be expelled.
	6.6.14				The work shall be organized so that the placing of concrete is efficient and continuous between specified or approved construction joints.
	6.6.15				Concrete shall be protected during hardening from direct sunlight, rain or running water.
	6.6.16				Heavy loads shall not be placed on concrete areas. Utmost care should be taken to prevent damage to the surface.
	6.6.17				The forms shall be removed without damage to the concrete. The use of shuttering oil to facilitate this activity shall be subject to approval. The forms        shall not be struck until the concrete has attained sufficient hardness.
	6.6.18				Anchor bolts shall be set in place and position by means of templates and held rigidly to prevent displacement while pouring concrete.
	6.7				Cube testing
	6.7.1				The minimum compressive strength at 28 days shall not be less than 27.6 MPa (4000 Psi)
	6.7.2				Contractor shall employ Company approved testing agency to perform field and laboratory testing for molded concrete cylinders test for slump temperature of concrete. Testing shall be in accordance with OG-SAMMS-097
	6.8				Curing
	6.8.1				Structural concrete shall be continuously cured in accordance with ACI 305 & ACI 308.
	6.8.2				Clean and portable water shall be used. Maximum total dissolved solids shall not exceed 1000 ppm.
	6.8.3				Water curing shall be continuous until the compressive strength has reached 70% of specified strength but not less than 7 days after placement.
	6.8.4				The saturated burlaps shall be covered with plasticized sheet vapor barrier of 0.15mm in thickness.
7.0	HSE Requirements
	7.1				The design and construction of formwork in accordance Saudi Client safety manual.
	7.2				Supervisor shall ensure that all necessary health and safety procedures during formwork, steel bar fixing and concreting.
	7.3				Supervisor shall ensure that all necessary health and safety procedures during the field survey, Site preparation, Setting out and excavation work.
	7.4				All laborers shall wear safety shoes, coverall and helmets at all times on site.
	7.5				Equipment shall be checked periodically and maintained in good condition.
	7.6				Work permit shall be obtained by the supervisor before commencing work.
	7.7				All relevant safety requirements of KOC Fire & safety regulations and KOC’s HSE requirements shall be conformed for all works that performed.
	7.8				All lifting equipments and accessories shall be with valid third party certificates.
	7.9				Nails protruding from used wooden formwork representing a potential hazard shall be removed immediately after striking and removing the formwork.
	7.10				Used and new materials shall be stored separately.
	7.11				Incase of night work, adequate lighting shall be provided.
	7.12				The supervisor shall be responsible for good housekeeping. Temporary and permanent construction materials such as wood, plywood, steel reinforcement and shutter panels shall be kept separately and stored on the job site in an orderly manner. Rejected or excess materials shall not be scattered on the site.
8.0	ATTACHMENTS
	8.1				Attachment No.1 - Checklist for concreting.