Complete Quality Manual Vol 2 Rev. 2010

THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION. ALL OTHER VERSIONS ARE CONSIDERED TO BE UNCONTROLLED AND MAY NOT BE USED FOR WORK CONTROLLING PURPOSES. DOCUMENT NO. MACO-QM-001 th 01 April 2009

QA / QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES

KINGDOM OF SAUDI ARABIA

P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281

DOCUMENT NO. MACO-QM-001

REV. 0

THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION. ALL OTHER VERSIONS ARE CONSIDERED TO BE UNCONTROLLED AND MAY NOT BE USED FOR WORK CONTROLLING PURPOSES. DOCUMENT NO. MACO-QM-001 th 01 APRIL 2009

QA/QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES

P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281

1 2 3 1 2 3

ISSUED FOR APPROVAL QA/QC Quality Manual SIGNATURE/DATEREVISION HISTORY:

Prepared By:

CHECKED BY

APPROVED BY

APPROVED BY

APT

YSB

NMZ

SMZ

Document Recipients:1. Gen. Manager 2. Asst. Gen. Manager 3. Business Dev. Manager 4. Project Managers 5. QA/QC Department 6. Project Engineers

Revision 1 April 1, 2009

DOCUMENT NO. MACO-QM-001 VOL. 2

REV. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUALMACO-QM-001VOL. 2

APPROVAL SHEET

Description Prepared By: Approved By: Approved By: Approved By:

Name A. P. Togle

DesignationQA/QC Senior Engineer Manar Arabian Corp.

Signature

Date

Y.S. Bahrawy N. M. Zahrani S. M. Zahrani

Projects Gen. Manager Assistant General Manager General Manager

-i-

Quality Manual Vol. 2

MACO-QM-001

QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUAL MACO-QM-001VOL. 2

REVISION HISTORY

Revision No. 0 1 2

Purpose of Revision Submitted for Approval.

Issue Date April 01, 2009

-iiQuality Manual Vol. 2 MACO-QM-001

QUALITY CONTROL/ASSURANCE MANUAL Quality Construction ProceduresDOCUMENT No. MACO-QM-001 REV. 0

TABLE OF CONTENTS QUALITY CONSTRUCTION PROCEDURES

SL NO.

PROCEDURE DESCRIPTION CIVIL WORKS

DOCUMENT NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

SURVEYING SITE PREPARATION EXCAVATION, TRENCHING, BACKFILLING & COMPACTING ASPHALT CONCRETE PAVING & BASE COURSE CONCRETE WORKS GROUTING WORKS PROTECTIVE COATING FOR BURIED CONCRETE WATERPROOFING, CAULKING AND SEALING PIPE INSTALLATION PROCEDURE CONCRETE BATCH PLANT MISCELLANEOUS METALS SITE NON-ELECTRICAL PROCEDURE STRUCTURAL STEEL JOINT SEALANTS PRESSURE TESTING THRUST BORINGPage 1 of 3

MACO-QCCP-001 MACO-QCCP-002 MACO-QCCP-003 MACO-QCCP-004 MACO-QCCP-005 MACO-QCCP-006 MACO-QCCP-007 MACO-QCCP-008 MACO-QCCP-009 MACO-QCCP-010 MACO-QCCP-011 MACO-QCCP-012 MACO-QCCP-013 MACO-QCCP-014 MACO-QCCP-015 MACO-QCCP-016MACO-QCP-TOC



SL NO.

PROCEDURE DESCRIPTION

DOCUMENT NO.

ELECTRICAL WORKS/INSTRUMENTATION WORKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 WIRES AND CABLES INSTALLATION PROCEDURE GROUNDING SYSTEMS PROCEDURES LOW & MEDIUM VOLTAGE CABLES INSTALLATION PROCEDURE. SWITCH BOARDS AND PANEL BOARDS PROCEDURE INSTRUMENT AND WIRING PROCEDURE INSTRUMENT CONTROL PANEL PROCEDURE FIRE ALARM SYSTEMS INSTALLATION OF LIGHTING SYSTEM POWER SYSTEMS INSTALLATION OF JUNCTION BOXES AND DEVICES INSTALLATION OF CABLE TRAYS INSTALLATION OF COMMUNICATION SYSTEMS INSTALLATION OF CONDUITS AND FITTINGS INSTALLATION OF DISCONNECT SWITCHES LOW VOLTAGE MOTOR CONTROL CENTER INSTALLATION OF DRY-TYPE TRANSFORMERS INSTALLATION OF OIL-FILLED TYPE TRANSFORMERSPage 2 of 3

MACO-QECP-001 MACO-QECP-002 MACO-QECP-003 MACO-QECP-004 MACO-QECP-005 MACO-QECP-006 MACO-QECP-007 MACO-QECP-008 MACO-QECP-009 MACO-QECP-010 MACO-QECP-011 MACO-QECP-012 MACO-QECP-013 MACO-QECP-014 MACO-QECP-015 MACO-QECP-016 MACO-QECP-017MACO-QCP-TOC


18 19

INSTALLATION OF BATTERIES AND CHARGERS UNDERGROUND ELECTRICAL DUCT BANKS/MANHOLES

MACO-QECP-018 MACO-QECP-019


SL NO.

PROCEDURE DESCRIPTION MECHANICAL WORKS

DOCUMENT NO.

1 2 3 4 5 6 7 8 9 10 11 12 13

INSIDE BUILDING PIPING AND FITTINGS PIPE SLEEVES ANCHORS, SUPPORTS AND THRUST BLOCKS VIBRATION ISOLATION AIR HANDLING UNIT AIR COLLED CONDENSING UNIT PACKAGE AIR CONDENSING UNIT DUCTWORKS DUCTWORKS ACCESSORIES DUCTWORKS INSULATION MECHANICAL IDENTIFICATION TESTING AND BALANCING OF MECHANICAL SYSTEMS WELDING OF STRUCTURAL AND PIPING-END-

MACO-QMCP-001 MACO-QMCP-002 MACO-QMCP-003 MACO-QMCP-004 MACO-QMCP-005 MACO-QMCP-006 MACO-QMCP-007 MACO-QMCP-008 MACO-QMCP-009 MACO-QMCP-010 MACO-QMCP-011 MACO-QMCP-012 MACO-QMCP-013

Page 3 of 3

MACO-QCP-TOC

QUALITY CONTROL/ASSURANCE MANUAL Construction ProceduresDOCUMENT No. MACO-QM-001 REV. 0

DOCUMENT TITLE:

PROCEDURE FOR: SURVEYING

DOCUMENT NO.: MACO-QCCP-001Index 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 Scope Purpose References Definitions Responsibilities Procedure Documentation Page 2 2 2 2 2 3 4

001 ISSUE NO.

04/09/09 ISSUE DATE

MACO-QCCP-001 DESCRIPTION

APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Surveying

Page 1 of 5

MACO-QCCP-001


SURVEYING1 Scope

This quality procedure covers setting up reference points and bench marks, vertical and horizontal setting out of all buildings, trench work, utility installations and other works forming part of the contract. 2 Purpose

The purpose of this quality procedure is to provide a documented procedure for all activities related to Surveying. 3 References IFC Drawings : 4 Definitions None 5 Responsibilities 5.1 The QC inspector shall inspect and prepare RFI for Proponent representative to verify accuracy of gathered survey report/data. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes (if any). 5.2 The surveyor shall perform actual survey and ensure that gathered survey report/data are accurate, recorded and reported. His responsibility includes but no limited to: 5.2.1 Performing all surveys for the duration of the contract to ensure that levels and locations conform to the design drawings, and shop/working drawings approved by Proponent Representative. 5.2.2 Making formal written requests to Proponent for data on survey control points related to the project prior to construction. 5.2.3 Verifying the figures on all Proponent furnished data and documents before laying out the work. Site Plot Plan

Surveying

Page 2 of 5

MACO-QCCP-001


5.2.4 Informing Proponent Representative if the validity of any survey monument is threatened, and take the necessary steps. 5.2.5 Obtaining approval of Proponent Representative if any survey control points will be disturbed or destroyed by construction activities. 5.2.6 Maintaining all Proponent established reference points and bench marks at all times during construction. Under the direction of Proponent Representative, replace any survey monuments damaged or disturbed by construction activity. 5.2.7 6 Procedure 6.1 All horizontal and vertical reference points and monuments shall be established accurately within a maximum tolerance of 5mm vertically and 10mm horizontally. 6.2 If the validity of any survey monument is threatened, at least three (3) reference or witness markers shall be placed for each point likely to be disturbed. Survey notes shall be submitted listing the relative positions of the reference markers to each other and to the points referencing at least 48 hours prior to disturbing or threatening the validity of the monument. 6.3 All data and grade sheets shall be submitted to Proponent Representative at least 48 hours prior to construction. The grade sheets shall show the vertical and horizontal relationships between the stakes and the design reference points shown on the drawings. 6.4 All survey field notes shall be kept in field at all times for inspection by Proponent Representative. 6.5 Prior to beginning trenching operations and during the progress of the work, sufficient stakes shall be set and maintained to show conformance with the Drawings. All stakes shall be located in such a way that they will not be disturbed by construction operations. 6.6 Construction stakes shall be placed at each wye connection, cleanout, and at every 10 meter station. 6.7 All elevations shall be based on Proponent datum scale. Established survey controls shall be checked regularly against the existing monuments Preparing accurate as-built survey and submission drawings.

Surveying

Page 3 of 5

MACO-QCCP-001


prior to layout of new structures/utilities. Sufficient stakes shall be set and maintained before and during the progress of the work. 7 Documentation 7.1 Form QCCP-001-01-SC Survey Checklist

Surveying

Page 4 of 5

MACO-QCCP-001


SURVEY CHECKLIST QCCP-001-01-SC

Contract No.: _________________________ Location: _________________________

Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

COORDINATES AS PER ACTUAL DRAWING

DIFF.

ELEVATION AS PER ACTUAL DRAWING

DIFF.

REMARKS

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SURVEYOR

Proponent REPRESENTATIVE

Signature: Name: Date:

Surveying

Page 5 of 5

MACO-QCCP-001


DOCUMENT TITLE:

PROCEDURE FOR: SITE PREPARATION

DOCUMENT NO.: MACO-QCCP-002Index 1 2 3 4 5 6 7 Scope Purpose References Definitions Responsibilities Procedure Documentation Page 2 2 2 2 3 3 8

001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Site Preparation

Page 1 of 9

MACO-QCCP-002


SITE PREPARATION1 Scope

1.1 Clearing and Grubbing works shall include but not limited to: removal of all vegetation, brush, rubbish, large stones and metallic debris occurring within the limit of construction. 1.2 Earth work shall include, but not limited to: excavation of soil and rock, removal and disposal of all unsuitable soil and rock material from the work site, placing and compacting of fill materials imported from borrow pits, trenching and trench backfilling and grading the site to the required elevations as shown on the drawings. 2 Purpose

The purpose of this quality procedure is to provide a procedure for all activities related to Site Preparation. 3 References

ASTM C136: ASTM D 3017:

Sieve Analysis of Fine and Coarse Aggregate Test Method for Moisture Content of Soil and Soil Aggregate Test Method for CBR of Laboratory Compacted Soil Test Method for Maximum Index Density Test Method for Minimum Index Density Test Method for Density Test Method for Moisture Index Density

ASTM D 1883: ASTM D 4253: ASTM D 4254: ASTM D 2937: ASTM D 698:

Royal Commission Specifications: 02251 02220Site Preparation

Compaction and Testing of Earthwork Structure Excavation and BackfillPage 2 of 9 MACO-QCCP-002


02221

Trenching, Bedding, Backfilling and Compacting

Construction Specifications:

4

Definitions Dewatering removal of excess water from the saturated soil mass. Imported or Borrowed Fill Material sand or calcareous clay of marine origin, classified as marl, or combination of both sand and marl. The maximum particle size shall be 100 mm, or one half the lift thickness whichever is less. Select Fill Material inorganic material and shall have 100% passing the 50mm sieve and from 0-20% passing the no. 200 sieve. That portion of the material passing the No. 40 sieve shall have a maximum liquid limit of 35 and maximum plasticity index of 12. Atterbergs limits are not required for select fill material with less than 15% fines passing the No. 200 sieve. Clearing shall consist of satisfactory removal and disposal of all types of vegetation and debris including grass, brush and rubbish. Grubbing shall consist of the removal and disposal of slumps and roots to a depth of 0.5 meters below ground within the limit of construction.

5 5.1

Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Site Preparation. They shall coordinate with the surveyor for the reference and with the QC Inspector and/or Independent Testing Laboratory Technician for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to backfilling and compacting. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted.

5.2

5.3

Site Preparation

Page 3 of 9

MACO-QCCP-002


6 6.1

Procedure Surveying 6.1.1 Surveying shall be carried out in accordance to Work Procedure QCCP-001, Surveying. 6.2 Clearing and Grubbing 6.2.1 All types of vegetation and debris including grass, brush and rubbish within the limit of construction shall be satisfactorily removed and disposed. 6.2.2 Stumps and roots to a depth of 0.5 meters below the ground within the limit of construction shall also be removed and disposed. 6.3 Earthwork 6.3.1 Excavation 6.3.1.1 Unclassified Excavation work shall be performed to remove all material which includes soil and rock necessary for grading and construction in accordance with the lines and grades shown in the plan. 6.3.1.2 All unsuitable materials encountered during excavation shall be removed and replaced with suitable materials and compacted as required. Bottoms of excavation shall be smooth and free of loose earth or sand. 6.3.1.3 Excavation for structures shall be made accurately to the lines, grades and elevations shown on the drawings. Trenches and foundation pits shall be of sufficient size to permit the placement and removal of forms for the full length and width of structure footings. The upper 150mm of soil in the bottom of all footing trenches shall be compacted to the densities required. 6.3.1.4 Excavation work adjacent to the existing utilities as specified in the Proponent Construction Safety Manual will be carried out by Hand Excavation. 6.3.1.5 Trenching:

Site Preparation

Page 4 of 9

MACO-QCCP-002


6.3.1.5.1 Trenches shall be excavated with sufficient width to provide free working space at both sides of the trench and around the installed items as required for joining, backfilling and compacting. 6.3.2 Excavation of building foundations shall be carried out in accordance with foundation design drawings up to 2.5M depth to remove sabkha materials. Select fill material shall be used within 0.6m of bottom of elevation of foundations, spread footings, or slabs on grade. During excavation and compaction, ground water table shall be lowered to minimum 0.6m below the surface under compaction using Well Point System of dewatering. Dewatering shall be carried out in accordance to Method Statement submitted by Dewatering Sub-Contractor and approved by Proponent Representative. Side slope of excavations shall be cut true and straight and shall be graded to the proper cross section. Unsuitable soil slopes shall be removed and the slopes properly prepared. The bottom of excavations shall be graded to the elevations and configurations as shown on the Drawings. Over excavations shall be backfilled with suitable material and compacted. All excavated materials that are unsatisfactory for use as fill or backfill shall be disposed of at a location designated by Proponent. Unsuitable material encountered below grade shall be removed and replaced with suitable fill material and compacted to density requirements, unless the Geotechnical Report or Proponent Representative stipulates another procedure. Bottoms of excavations shall be smooth and free of loose earth or sand. Any soft or loose areas of insufficient bearing, as determined by Proponent Representative, shall be compacted to the density requirements. Excavation for structures shall be made accurately to the lines, grades and elevations shown in the drawings. Foundation pits shall be of sufficient size to permit the placement and removal of forms for the full length and width of structure footings and foundations shown. Rock or other hard material shall be cleaned of loose debris and cut to a firm surface, either level, stepped, or serrated, as shown or as directed. Loose disintegrated rock and thin strata shallPage 5 of 9 MACO-QCCP-002

6.3.3

6.3.4

6.3.5

6.3.6

6.3.7

6.3.8

Site Preparation


be removed. When concrete or masonry is to be placed in an excavated area, special care shall be taken not to disturb the bottom of the excavation. Excavation to the final grade level shall not be made until just before the concrete or masonry is to be placed. 6.3.9 Excavation works adjacent to the existing utilities shall be carried out by hand.

6.3.10 All general areas (i.e. parking area, paved areas in addition to the building foot prints) shall be excavated to a minimum depth of 0.6m to remove existing sabkha to minimize the capillary action resulting in sabkha contamination of the backfilled areas. 6.4 Fill 6.4.1 Before placement of fill or backfill material, the following shall be observed: 6.4.1.1 Areas to receive fill shall be free of roots, trash, or other foreign material. 6.4.1.2 All areas to receive fill shall have the in-site soil proof rolled and inspected, after clearing and grubbing, for soft spots or loose zones. 6.4.1.3 All observed soft spots or loose zones shall be compacted in-place or excavated to firm soil and replaced with properly compacted fill. 6.4.2 Surface protection shall be provided where clean sand or dune sand is used for fill/bedding material. A cap layer of compacted cohesive material 150 to 300mm in thickness will be placed. Capping material shall have a maximum size of one-half lift thickness or 75mm, whichever is less, and shall have between 11-35% passing the No. 200 sieve. The capping material shall have a maximum liquid limit of 35 and maximum plasticity index of 12, as per ASTM D4318. Final slope shall be protected from erosion. 6.4.3 Fill materials shall be placed in successive horizontal lifts or layers not to exceed 200 mm in depth. Each layer, before starting the next, shall be leveled and smoothed by means of power driven graders, bulldozers or other suitable equipment. Hauling and spreading equipment shall be operated over the full width of each layer.

Site Preparation

Page 6 of 9

MACO-QCCP-002


6.4.4 Each layer of fill material shall be moistened or dried to uniform moisture content suitable for maximum compaction and then thoroughly compacted by rolling with tamping or pneumatic tired rollers or through wheel power rollers. At least one roller shall be operated continuously for each 100 cm, or fraction thereof, per hour. When several embankments, each of small area, are so isolated from each other that one roller cannot compact them satisfactorily, additional rollers shall be provided. All fills shall be compacted to 85% relative density as defined by ASTM D4253 and ASTM D4254 for cohesion-less materials, or 95% of the maximum density as determined by ASTM D1557 for cohesive materials. 6.4.5 Backfilling adjacent to structures shall be placed and compacted uniformly in such manner as to prevent wedging action or eccentric loading upon or adjacent to the structures. Slopes bounding or within areas to be backfilled shall be stepped or serrated to prevent sliding of the fill. During backfilling operations and in the formations of embankments, equipment that will overload the structure in passing over and compacting this fill shall not be used. 6.4.6 Prior to importing borrow materials and/or transporting fill material to Work site areas requiring fill, Proponent Representative reserves the right to inspect and test the fill material for conformity with the Specifications. Fill material which does not meet the requirements of Specifications shall not be used and, if on the worksite, shall be removed from the worksite. 6.5 Compaction and Testing 6.5.1 Prior to compaction of fill, a field test section using the intended compaction equipment shall be performed to determine the proper lift thickness to achieve the necessary density requirement. 6.5.2 In-place density and moisture content of soils shall be determined by the sand cone method per ASTM D1556, nuclear method per ASTM D2922, the rubber balloon method per ASTM D2167, or the drivecylinder method per ASTM D2937. Acceptance testing of in-place density and moisture content (field density testing) on compacted fill will be performed at the following rates: 6.5.2.1 Under all foundations one test every 1000 ft2. (90 m2.) of each lift. 6.5.2.2 Under area paving one test every 2000 ft2. (180m2.) each lift. of

Site Preparation

Page 7 of 9

MACO-QCCP-002


6.5.2.3 Road base and sub-base one test every 2000 ft2. (180m2.) of base or sub-base. 6.5.2.4 Backfill of trenches one test for every 50 linear ft. (15m) of each lift. 6.5.2.5 General fill one test every 5000 ft2. (460m2) of lift. each

6.5.3 As a minimum, at least one in-place density test shall be performed on every lift of fill and further placement shall not be allowed until the required density has been achieved. 6.5.4 The number of tests shall be increased if a visual inspection determines that the moisture content is not uniform or if the compacting effort is variable and not considered sufficient to attain the specified density. 7 7.1 Documentation Form No. QCCO-002-01-SP Site Preparation Checklist

Site Preparation

Page 8 of 9

MACO-QCCP-002


SITE PREPARATION CHECKLIST QCCP-002-01-SP


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3 4 5 6 7

All backfilling layer should be as of indicated in the contract drawing. Select fill is of Clint Specification or as approved by the client. Do not allow layers to exceed 300mm in thickness before compaction. Compact each layers in accordance with Royal Commission for Jubail & Yanbus Standards. The bottom of the trench shall be free of sharp or loose rock, debris or foreign matter. Cable or pipe shall be laid on a 150mm thick clean sand bed. The bed should be compacted uniformly to provide even bearing for pipes.

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SUPERVISOR



Site Preparation

Page 9 of 9

MACO-QCCP-002


DOCUMENT TITLE:

PROCEDURE FOR: EXCAVATION, TRENCHING, BACKFILLING AND COMPACTING


001 ISSUE NO.

03/21/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Excavation, Trenching, Backfilling and Compacting

Page 1 of 7

MACO-QCCP-003


EXCAVATION, TRENCHING, BACKFILLING AND COMPACTING1 Scope

1.1 This procedure covers the trenching, excavation, backfilling and compacting building and other structures and utility lines; water and sewer pipes, drainage pipes, which also includes manholes, cleanouts and boxes, removal and disposal of excess excavation material and importing required bedding and fill material, installation of cable tiles and warning tapes. 2 Purpose

The purpose of this quality procedure is to provide a documented procedure for all activities related to Excavation, Trenching, Backfilling and Compacting. 3 References Sieve Analysis of Fine and Coarse Aggregate Test Method for Moisture Content of Soil and Soil Aggregate Test Method for CBR of Laboratory Compacted Soil Test Method for Maximum Index Density Test Method for Minimum Index Density Test Method for Density Test Method for Moisture Index Density Nuclear Test Method for Soil Moisture Density Test Method for Moisture Density Relations Classification of Soil for Engineering Purpose Particle Size Analysis of Soils

ASTM C136: ASTM D 3017:

ASTM D 1883: ASTM D 4253: ASTM D 4254: ASTM D 2937: ASTM D 698: ASTM D 2292: ASTM D 1557: ASTM D 2487: ASTM D 422:


Page 2 of 7

MACO-QCCP-003


Royal Commission Specifications: 02251 02220 02221 02210 02110 02220 Compaction and Testing of Earthwork Structure Excavation and Backfill Trenching, Bedding, Backfilling and Compacting Earth Work Clearing and Grubbing Structure Excavation & Backfill

Construction Specifications

4

Definitions None

5 5.1

Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Excavation, Trenching and Backfilling. They shall coordinate with the surveyor for the reference and with the QC Inspector and/or Independent Testing Laboratory Technician for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to backfilling and compacting. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted.

5.2

5.3

6 6.1

Procedure Surveying


Page 3 of 7

MACO-QCCP-003


6.1.1 Surveying shall be carried out in accordance to Work Procedure QCCP-001, Surveying. 6.2 Site Preparation 6.2.1 Earthworks shall be carried out in accordance with Work Procedure QCCP-002, Site Preparation. 6.3 Excavation/Trenching 6.3.1 Excavation/Trenching shall be performed as indicated on the plans and standard details in whatever material encountered. All excavations for structures, utility pipes, appurtenances or cables shall be made to an extent that will provide sufficient space to work conveniently around the structure or pipe to be installed. 6.3.2 All unsuitable surplus materials removed during excavation or trenching shall be removed from site and disposed of at a Government approved dump site. All materials suitable for backfill shall be used. 6.3.3 Excavation/Trenching over 1.2M deep shall be provided with sides sloped back to the natural repose of the soil to avoid caving. Sides which can not be sloped to the natural repose because of adjacent structures or ground condition shall be shored adequately to resist earth movement and protect workers. 6.3.4 If required for construction, before excavation, an approved dewatering system shall be installed and operated when necessary to lower the groundwater. All excavation and trenches shall be kept dry until the structures, pipes and appurtenances to be built are completed.

6.4

Structure Fill and Backfill 6.4.1 Compaction shall have a minimum of 70% relative density (ASTM D4253/4254) or 95% standard proctor density (ASTM D698) whichever is applicable and gives the greater density. 6.4.2 Fill and backfill under structures shall be select fill or coarse aggregate and fine aggregate when indicated or specified for use under structures, and conforming to requirements for coarse and fine aggregate. 6.4.3 Fill material shall be placed in lifts not exceeding 150 mm in thickness. Unless otherwise indicated or specified, each layer shall be compacted to 95% of the maximum density as determined by ASTM


Page 4 of 7

MACO-QCCP-003


D698 for cohesive material and within 1 % optimum moisture content or 70% relative density as determined by ASTM D 4253/4254 for cohesion less material. 6.4.4 Backfill against or on structures shall not be placed until they have attained sufficient strength to support the loads (including construction loads) to which they will be subjected, without distortion, cracking, or other damage. Special leak tests shall be provided, if required, as soon as practicable after structures are structurally adequate and other necessary work has been done. Backfilling shall be promptly started after completion of tests. Unequal soil pressure shall be avoided by depositing material evenly around structure. 6.4.5 The sides of all concrete foundations shall be primed and top coated with asphalt emulsion damp-proofing prior to backfilling. 6.5 Trench Backfill 6.5.1 The bottom of the trench shall be free of rock, sharp debris or foreign matter that could cause damage to pipes, cables or other new construction. 6.5.2 Cables or pipes shall be laid on a clean sand bed compacted to 70% relative density per ASTM D4253 and 4254. The bed shall be compacted uniformly to provide even bearing for pipes. After pipes have been laid, tested and approved; fillings shall be placed evenly on both sides of the pipes and periodically compacted to maintain equal pressure on the pipe. Backfilling shall be done in 150 mm lifts or half the pipe diameter whichever is greater until a depth of 300mm of fill over the pipe is obtained. 6.5.3 The depth of the trench shall be dug deep enough to provide a minimum ground cover above the top of the pipe and a ground bed of at least 150mm in depth below the bottom of the pipe. 6.5.4 Fill material shall be placed and built-up in successive layers and compacted by tamping, until it has reached the required elevation. Each layer shall be sloped to drain during construction. Layers shall not be allowed to exceed 200mm in thickness before compaction. Each layer of material shall be compacted by the use of rollers or other means so as to secure a dense, stable and thoroughly compacted mass. Where mobile mechanical equipment cannot be used, the materials shall be thoroughly compacted by the use of power driven tampers.


Page 5 of 7

MACO-QCCP-003


6.5.5 Cables or pipes shall be embedded all around with at least 150mm of compacted clean sand unless otherwise indicated, having minimum 70% relative density per ASTM D4253 and D4254.

6.6 Testing 6.6.1 In-place density test shall be performed in accordance with ASTM D1556, D2922 or D23167 after compaction of each lift to verify that the specified degree of compaction has been achieved. At least one in-place density test for every 90m2 of compacted soil shall be performed or for every layer or fill. Spacing between all test locations shall be approximately equal. 6.6.2 Should the work in question fail to meet the establish criteria for testing, remedial work shall be performed and re-tested to the satisfaction of the Proponent Representative.

6.7

Reinstatement 6.7.1 All trench excavations shall be restored so its surface contour blends in with the surrounding area. Areas of roadways and pavement shall be excavated as necessary and restored. 6.7.2 To install pipe, cable or conduits under existing pavement, pavement of the area shall be saw-cut as needed and restored to the original condition.

7 7.1

DOCUMENTATION Form QCCP-003-01-EP Excavation Checklist


Page 6 of 7

MACO-QCCP-003


EXCAVATION CHECKLIST QCCP-003-01-EP


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3 4 5 6 7

All backfilling layer should be as of indicated in the contract drawing. Select fill is of Clint Specification or as approved by the client. Do not allow layers to exceed 300mm in thickness before compaction. Compact each layers in accordance with Royal Commission for Jubail & Yanbus Standards. The bottom of the trench shall be free of sharp or loose rock, debris or foreign matter. Cable or pipe shall be laid on a 150mm thick clean sand bed. The bed should be compacted uniformly to provide even bearing for pipes.

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SUPERVISOR




Page 7 of 7

MACO-QCCP-003


DOCUMENT TITLE:

PROCEDURE FOR: ASPHALT CONCRETE PAVING & BASE COURSE


001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Asphalt Concrete Paving and Base Course

Page 1 of 9

MACO-QCCP-004


ASPHALT CONCRETE PAVING AND BASE COURSE1 Scope

1.1 This procedure includes, but is not limited to sub-grade preparation, aggregate base coarse, prime coat, tack coat, asphalt concrete paving, sampling and testing for the new construction of roads, driveways and parking areas as indicated in the Drawings. 2 Purpose

2.1 The purpose of this quality procedure is to provide a documented procedure for all activities related to Base Course application and construction of Asphalt Concrete Paving. 3 References

ASTM C88: ASTM C136: ASTM D1559: ASTM D1883: ASTM D2922: ASTM D4254: ASTM D4318:

Test Method for Sounding of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate Test Method for Sieve Analysis of Fine and Course Aggregate Test Method for Resistance to Plastic Flow of Bituminous Mixture Test Method for CBR (California Bearing Ratio) of Laboratory Compacted Soil Test Method for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth) Test Method for Maximum Index Density and Unit Weight of Soil and Calculation of Relative Density Test Method for Liquid Limit, Plastic Limit, and Plastic Index of Soil

Royal Commission Standards: 02555 Asphalt Concrete Pavement


Page 2 of 9

MACO-QCCP-004


4

Definitions Primer Coat Homogeneous, medium curing, liquid asphalt MC-70 conforming to Saudi Aramco Standards A973 or MC-250 conforming to Saudi Aramco Standard A974. Tack Coat Shall be RC 250 conforming to Saudi Aramco Standards A971 or RC-800, conforming to Saudi Aramco Standard A972.

5 5.1

Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Asphalt Concrete Paving. They shall coordinate with the QC Inspector for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to Asphalt Concrete Paving. He shall also coordinate with the Independent Testing Laboratory Technician for inspection and testing requirements. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted. Procedure 6.1 General Requirements 6.1.1 Job-mix design shall be submitted to the Proponent Representative for approval prior to start of work, or shall combine the mineral aggregate and asphalt in such proportion as to produce a mixture conforming the client specification. 6.1.2 Earthwork shall be performed in accordance with Work Procedure QCCP-002, Site Preparation. 6.2 Sub-Grade 6.2.1 Existing asphalt or other materials identified to be demolished as shown on the drawings shall be removed prior to the commencement of sub-grade cut/fill. Asphalt shall be saw-cut to provide clean, neat vertical edges that will provide a suitable surface for matching of new asphalt.

5.2

5.3

6


Page 3 of 9

MACO-QCCP-004


6.2.2 Unless otherwise specified, sub-grade shall be compacted to 95% of the maximum dry density per ASTM D1557 or AASHTO T180 method D) while within 1.5% of the optimum moisture content or to 85% of relative density determined by ASTM D4253 and D4254. 6.2.3 All holes, ruts, soft places, and other defects shall be corrected. In no case shall the sub-base or base course be placed on soft or unstable material, or over areas that are not drained. 6.2.4 If the sub-grade is dusty or muddy, operations shall be delayed until it is in a condition satisfactory to the Proponent Representative. 6.2.5 Prior to delivery of materials for the base course, the road bed surface shall be prepared by sprinkling, blading, rolling and lightly scarifying where necessary, until the proper crown is obtained. When compacted and ready for base course construction, the road bed shall be well compacted, smooth hard and uniform, all irregularities having been bladed out and rolled smooth. 6.2.6 After the road bed has been prepared, it shall be maintained true to cross section and grade until the base course is completed. The road bed of the entire project shall be maintained from the time the work is started until covered with the base course. 6.2.7 The sub-grade shall be offered for inspection and approval by the Proponent Representative, prior to starting construction of the sub-base or base course on any portion of the work. 6.3 Base Course 6.3.1 The stone base course and sub-base shall be laid in two layers each and compacted. 6.3.2 Sub-base course shall be provided only in fill sections where fill material has a CBR of 5% or less. The sub-base shall have a minimum CBR of 15% at 95% compaction. 6.3.3 The sub-grade shall be kept drained during the placing and compacting of the base course or sub-base surface. 6.3.4 Base course material shall not be placed until the sub-grade upon which it is to be placed has been approved by Proponent Representative. Base course material shall be placed and compacted in layers not to exceed 150 mm thickness after compaction.


Page 4 of 9

MACO-QCCP-004


6.3.5 While at optimum moisture (1-%) the sub-base or base materials shall be compacted with equipment capable of obtaining the desired density to the full depth of the respective layer. The rolling shall continue until the base and sub-base are compacted to not less than (100% for the base and 95% for the sub-base) of the maximum laboratory dry density as determined by ASTM D1557, or AASHTO T180. In-place density shall be measured by ASTM D2922 or ASTM D1556 or other approved methods. Testing shall be conducted at a rate of one test every 2000 ft. (180m) of base or sub-base. 6.3.6 Following the construction of the aggregate base, the compacted base course shall be maintained by blading, brooming and otherwise maintaining the base, keeping it free from raveling, and other defects until such time as the bituminous prime coat or other surface is applied. Water shall be applied at such time and in such quantities as directed by the Proponent Representative. 6.4 Prime Coat Application: 6.4.1 The prime coat shall be applied and shall consist of the MC-70 conforming to the Saudi Aramco Standard A-973 or MC-250 conforming to Saudi Aramco Standard A-974. A prime coat shall consist of the initial application of liquid asphalt into the surface of non-asphalt base course. 6.4.2 Immediately before applying the primer bituminous material, the surface shall cleaned of all loose dirt and other objectionable materials with a power broom, hand broom, or blower. If so ordered by the Proponent Representative, the surface shall be lightly bladed and rolled immediately prior to the application of the bituminous material, in which case brooming or blowing will not be required. A light application of water shall be lightly applied, if required, just before the application of bituminous material. 6.4.3 Prime coat shall be applied only when the surface to be treated is dry and when the temperature in the shade is 8C and rising. Prime coat shall not be applied when the weather is foggy or rainy or in a sand storm. Bituminous material shall be applied by means of a distributor at a rate between 0.65 and 1.75 liters/M and at a temperature between 50C to 80C. If the material is applied in two lanes, there shall be an overlap of at least 200 mm. Any prescribed application may be divided in two applications to prevent plowing of the surface and additional bituminous material shall be applied where surface conditions indicate it is required. 6.4.4 The primed surface shall be kept free from all traffic and in a clean condition pending placement of the covering asphaltic concrete pavement.Asphalt Concrete Paving and Base Course Page 5 of 9 MACO-QCCP-004


A minimum period of 24 hours shall be allowed for the absorption and curing of the prime coat prior to placement of covering pavement. 6.4.5 Surfaces of manhole cover and frames shall be coated with oil to prevent bond with asphalt pavement. These surfaces shall not be bonded with primer or tack coat.

6.5

Tack Coat Application: 6.5.1 The asphalt binder course shall be laid in two layers as per SAESQ-006. 6.5.2 The tack coat shall be of RC-250 conforming to Saudi Aramco Standard A-971 or RC-800, conforming to Saudi Aramco Standard A-972. 6.5.3 Tack coat shall be applied to all concrete surfaces that will be in contact with asphalt concrete pavement. Tack coat applications shall take place prior to the paving operations and will include contact surfaces of concrete gutters and other drainage structures. 6.5.4 Tack coat shall be applied between the binder course and the surface course; new and old asphalt surface, and vertical cut of adjacent to new asphalt. If application of the surface is delayed by more than 3 days, or if dirt, sand or other impurities have contaminated the tack coat, then a new tack coat shall be applied after the original one has been swept clean. 6.5.5 The bituminous material shall be applied on the binder course by means of a bituminous distributor at a maximum rate of 0.25 liters/M or as directed by the Proponent Representative. A hand broom shall be used for application of the tack coat to concrete surfaces not covered by the bituminous distributor. 6.5.6 Tack coat shall not be placed during rainy weather, or when the moisture on the surface to be paved would prevent proper bond. 6.5.7 Tack coat shall be applied to contact surfaces of curbs, gutters and berm walls.

6.6

Placement of Asphaltic Concrete 6.6.1 Asphalt shall be petroleum asphalt cement, Grade 60-70 penetration, conforming to Saudi Aramco Standard A-970.


Page 6 of 9

MACO-QCCP-004


6.6.2 Asphaltic concrete material shall not be accepted unless it is covered with tarpaulins until unloaded, and unless it has a temperature of at least 139C at the time of spreading and compaction.

6.6.3 Placement and compaction of the bituminous mixture shall progress in sections not more than 90M in length. The bituminous mixture shall be spread, shaped and finished with the power machine with automatic adjustable grade controlled by a ski or a straight line. The mixture shall be placed one-half width or one traffic lane at a time. After the first width has been compacted, the second width shall be placed, finished and compacted as specified for the first width. Asphaltic concrete shall not be placed when the atmosphere temperature is below 10C, nor during fog, rain, wind or other unsuitable conditions. 6.6.4 Asphaltic concrete material shall be spread in a manner which requires the least handling. When thickness of finished pavement will be 60 mm or less, material shall be spread in one layer. Maximum thickness of layer shall not exceed 120 mm in loose measurement. 6.6.5 After a layer has been placed the full width, the surface shall be rolled. Rolling shall be longitudinal, and shall commence at the outer edge of the road overlapping it and progress towards the center. Rolling shall continue until the surface is of uniform texture and degree of compaction is achieved, and is true to grade and cross section. Under no circumstances shall the center of the surface course be rolled first. 6.6.6 Asphalt Compaction Density requirement shall be equal to or greater than 96% of the Marshall Density of each day production per ASTM D1559. 6.7 Inspection and Testing: 6.7.1 In-place density test shall be performed in accordance with ASTM D1556, D2922 or D23167 after compaction of each lift to verify that the specified degree of compaction has been achieved. At least one in-place density test for every 90m2 of compacted soil shall be performed or for every layer or fill. Spacing between all test locations shall be approximately equal. 6.7.2 Should the work in question fail to meet the establish criteria for testing, remedial work shall be performed and re-tested to the satisfaction of the Proponent Representative. 6.8 ReinstatementPage 7 of 9 MACO-QCCP-004



6.8.1 All trench excavations shall be restored so its surface contour blends in with the surrounding area. Areas of roadways and pavement shall be excavated as necessary and restored. 6.8.2 To install pipe, cable or conduits under existing pavement, pavement of the area shall be saw-cut as needed and restored to the original condition.

7 7.1

DOCUMENTATION Form QCCP-004-01-CP Base Course and Asphalt Concrete Paving Checklist


Page 8 of 9

MACO-QCCP-004


BASE COURSE & ASPHALT CONCRETE PAVING CHECKLIST QCCP-004-01-CP


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3 4 5 6 7

Sub-grade shall be compacted as per the client specification. Base course shall be compacted as per the client specification. Prime Coat shall be applied as per the client specification. Tack Coat shall be applied as per the client specification. Placement of Asphalt Concrete shall be applied as per the client specification. Thickness Tolerance: Measurement of any core shall not be deficiently by more than 10mm or 15% of the design thickness. Asphalt Concrete Mixture shall be applied as per the client specification.

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SUPERVISOR




Page 9 of 9

MACO-QCCP-004


DOCUMENT TITLE:

PROCEDURE FOR: CONCRETE WORKS

DOCUMENT NO.: MACO-QCCP-005Index 1 2 3 4 5 6 7 Page Scope Purpose References Materials Procedure Inspection & Testing Documentation 2 2 2 2 4 10 10

001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Concrete Works

Page 1 of 14

MACO-QCCP-005


CONCRETE WORKS1 Scope 1.1 This document covers formworks, rebars, placing, finishing, curing and joints associated with construction of concrete structures. 2 Purpose 2.1 The purpose of this procedure is to describe the minimum requirements in construction of reinforced cement concrete work. 3 References

ACI 318

Building Code Requirements of Structural Concrete

Royal Commission Standards: 03348 Casts-In-Place Concrete

4

Materials: 4.1 Definitions: 4.1.1 Structural Concrete: All reinforced concrete including concrete with minimum reinforcement for temperature and shrinkage control. The 28 day design compressive strength (ASTM C39) shall be 35 MPa. or as required by design drawing. 4.1.2 Non-structural Concrete: Un-reinforced concrete of no significant structural value such as lean concrete for sub-slabs, mass concrete etc. The minimum 28 day compressive strength (ASTM C39) shall be 14 MPa. 4.2 Water: 4.2.1 Potable water shall be used in the production of concrete, placement of concrete, production of ice used in concrete operations, washing aggregates, cooling aggregates, curing concrete, and cleaning, wetting and cooling the forms.

Concrete Works

Page 2 of 14

MACO-QCCP-005


4.3

Cement: 4.3.1 Portland cement shall conform to ASTM C150, as specified by the client.

4.4

Aggregate: 4.4.1 Aggregates shall conform to ASTM C33. 4.4.2 Fine and coarse aggregate shall be considered as separate ingredients and combined gradation shall be the approved mix design. 4.4.3 Carbonate and dolomite materials shall not be permitted.

4.5

Admixtures: 4.5.1 Chemical admixtures shall conform to ASTM C494 and shall be used in accordance with manufacturers recommendations. The admixtures shall not reduce the strength of the concrete. 4.5.2 Silica Fume: Silica fume used as cement replacement shall be in accordance with ASTM C1240.

4.6

Reinforcing Steel: 4.6.1 Grade for fusion Bonded Epoxy Coated Rebars (FBECR) and Uncoated Rebars Reinforcement shall be new and to the following grades: General reinforcement shall be deformed billet steel conforming to ASTM A615/A615M, Grade 60 with a specified yield strength of 414 MPa. Welded steel wire fabric shall conform to ASTM A185 for plain fabric and to ASTM A497 for deformed fabric. Testing of tensile strength, bending and elongation in accordance with ASTM A370 for each diameter of reinforcing bars shall be done for every 200 tons of site delivered steel.

4.7

Curing Materials: 4.7.1 Hessian shall be in accordance with AASHTO M182 and shall weigh 0.29 kg/m2.

Concrete Works

Page 3 of 14

MACO-QCCP-005


4.7.2 Impervious Sheeting shall be polyethylene, and in accordance with ASTM C171. 4.8 Colored Concrete: 4.8.1 Concrete used for underground duct encasement shall have a minimum compressive strength of 20 MPa. As required by design drawing. Aggregate size shall be as per concrete mix design. 4.8.2 Concrete encasement for underground electrical ducts shall be colored red by adding 1 Kg. of red oxide powder per 100 Kg. of cement. 4.9 Accessories: 4.9.1 All sleeves, inserts, anchor bolts, water stops and other embedded items shall be installed in accordance with the design drawings and supported against displacement. 4.9.2 The coating materials in accordance with the coating system specifications shall be used. 4.9.3 For critical applications, coating materials from clientapproved manufacturers shall only be used. 4.9.4 The type of abrasive to be used shall be determined by the degree, of cleanliness and roughness required for the coating system. Abrasives commonly used are sand, garnet and grit.

5

Procedure 5.1 GENERAL: 5.1.1 All structural concrete shall be planned mix. Client shall approve batching plant and the design of the concrete mix to be used. 5.1.2 All plant facilities are subject to random inspection for compliance with the approved design mix. 5.1.3 The mix design will encompass: Compressive Strength Cement Content and Type

Concrete Works

Page 4 of 14

MACO-QCCP-005


Fine and Coarse Aggregates Water Cement Ratio Air Content Slump Admixtures if any. 5.2 FORM WORKS: 5.2.1 Comply with provisions of ACI 347-78 Recommended Practice for Concrete Formwork for design and construction. 5.2.2 Formwork will be inspected for the following: Dimensional Accuracy as per drawings. Line and level with tolerances. Metal embeds and inserts are at accurate positions. Firmness of forms and supports. Form surfaces must be clean and coated with approved form release agent. Chamfer strips to be used on exposed corners. Inside of forms must be cleared of all debris before placing concrete. Install and properly tighten all form ties or clamps as specified. All threads should fully engage the nut or coupling. 5.3 REINFORCEMENT: 5.3.1 All reinforcement fabrication shall be carried out by qualified craftsmen. 5.3.2 Epoxy coated rebars shall be bent using fiber or plastic mandrels to prevent damage to coatings. 5.3.3 Any damage coating shall be repaired using epoxy touch up paint kit. 5.3.4 Place reinforcement as per correct size and spacing. Position, support and secure reinforcement against displacement using pre-cast concrete blocks or PVC chairs. 5.3.5 Minimum bend diameter shall be as per the table below (Refer to Table 7.2 of ACI 318)

Concrete Works

Page 5 of 14

MACO-QCCP-005


Rebar Size 10 mm to 25 mm Dia. 28 mm to 36 mm Dia. 43 mm to 57 mm Dia.

Minimum Dia. Of Bend 6 times diameter of bar. 8 times diameter of bar. 10 times diameter of bar.

5.3.6 Adequate cover over reinforcement as required by codes is needed for protection of steel and long term durability of the concrete. The following minimum concrete cover shall be provided for reinforcement, unless otherwise shown in the construction drawings:DESCRIPTION COVER INCH

a b

c

Clear cover concrete in contact with soil (all Substructures.) Concrete exposed to weather: i) 18mm to 57mm dia. bar ii) 16mm and below Concrete not exposed to weather or in contact with ground: i) Slab, wall and joists 43 to 57mm 36mm and below ii) Beam and Column: Primary reinforcement, ties, stirrups, spirals. iii) Shells, folded plate numbers 18mm dia. and more 16mm dia. and lower

3 in. 2 in. 1-1/2 in.

1-1/2 in. in. 1-1/2 in. in. in.

5.3.7 Minimum splice length shall be as shown on the drawings. 5.3.8 Hooks and bends, including minimum extensions, shall be made in accordance with the approved shop drawings. 5.3.9 When rebar details are shown on the design drawing marked Issued for Construction the reinforcing steel shall be fabricated in accordance with these schedules. 5.3.10 Reinforcing steel, at the time of placing in the forms and prior to concrete pour, shall be free from mud, oil, or other deleterious coatings that will reduce the bond.

Concrete Works

Page 6 of 14

MACO-QCCP-005


5.3.11 Welding of crossing bars shall not be permitted for assembly of reinforcement unless authorized by the client. 5.3.12 Handling and fabrication of epoxy coated reinforcement shall be in accordance with ASTM A775 Appendix and concrete reinforcing steel. 5.4 CONCRETE PLACING: 5.4.1 Concrete placement is accomplished with buckets, hoppers, chutes, drop pipes, conveyor belts or pumps as required, in accordance with ACI304-R. 5.4.2 All structural concrete shall pour over lean concrete along with vapor barrier. 5.4.3 Deposit concrete continuously and at such a rate that the underlying concrete is still plastic. 5.4.4 The method of holding water stop in the forms should ensure that it cannot bend to form cavities during concreting. 5.4.5 Bars and embedded items should be held securely in the proper position by suitable supports and ties to prevent displacement during concreting. 5.4.6 Ensure proper vibration. Over vibration should be avoided to prevent segregation. 5.4.7 Vibrators are not to be used to transfer concrete inside forms. Any movement of concrete is to be by hand shovel. Re-tempering of concrete is not allowed. 5.4.8 Vertical drop of concrete shall not exceed 1.5 meters. 5.4.9 Dampen the sub-grade and forms to prevent moisture loss at the base of the slab prior to pouring. 5.5 HOT WEATHER CONCRETING: 5.5.1 Hot weather may lead to problems in mixing, placing and curing hydraulic cement concrete that can adversely affect the properties and serviceability of the concrete. Most of these problems relate to the increase rate of cement hydration at higher temperature and the increase evaporation rate of moisture from the freshly mixed concrete. The rate of cement hydration is dependent upon concrete temperature, cementConcrete Works Page 7 of 14 MACO-QCCP-005


composition and fineness, and admixtures used. Preparations and procedures are required to reduce the undesirable effects of hot weather concreting in general type of construction. Generally, if concrete strengths are satisfactory and curing practices are sufficient to avoid undesirable drying of surfaces, durability of hot weather concrete should not be greatly different from similar concrete placed at normal temperature. 5.5.2 The following list of practices and measures to reduce or avoid the potential problems of hot weather concreting: Use concrete materials and proportions with satisfactory records in field use under hot weather conditions. Use cool concrete. Use a concrete consistency that permits rapid placement and effective consolidation. Transport, place, consolidate and finish concrete with least delay. Plan the job to avoid adverse exposure of the concrete to the environment; schedule placing operations during times of the day or night when weather conditions are favorable. Protect the concrete against moisture loss at all times during placing and during its curing period. Protect freshly placed concrete from premature drying. 5.6 CONCRETE CURING AND PROTECTION: 5.6.1 Protect freshly placed concrete from premature drying. In extremely dry and hot weather, fogging of the surrounding area may be required. 5.6.2 Water for curing shall be sweet water. 5.6.3 Start curing as soon as the concrete surface has hardened sufficiently. Curing of concrete shall strictly continue as per ACI/RC Specifications. 5.6.4 A plasticized sheet vapor barrier shall be placed beneath slabs on grade. Outdoor sidewalks are exempted from this requirement. 5.6.5 A plasticized sheet vapor barrier or lean concrete shall be placed beneath concrete foundations. Lean concrete thickness shall be as per conceptual drawings/scope of work. i.e. 100mm. 5.6.6 All concrete surfaces in direct contact with earth shall be coated with two (2) coats of coal.

Concrete Works

Page 8 of 14

MACO-QCCP-005


5.7

JOINTS: 5.7.1 Construction Joint: Locate construction joint as per design drawings. Pattern of reinforcement for construction joint and other joints shall be submitted to Proponent for approval. Unless otherwise specified, the surface of the previously placed concrete shall be prepared by exposing aggregate and removing laitance, loose particles. And damaged concrete. Immediately before placing new concrete, the joint surface shall be thoroughly saturated and excess surface water shall be removed. Reinforcing steel and mesh shall be continued across construction joints. 5.7.2 CONSTRUCTION JOINT: Construction joints shall be by saw cutting and location shall be as per design drawings. Start cutting as soon as concrete has hardened sufficiently to prevent dislodgement of aggregates. Saw a continuous slot to a depth of one-fourth the thickness of the slab. 5.7.3 EXPANSION JOINT: General: Width of joints shall be (13 mm) minimum and 1 (25 mm) maximum. Sides of joints shall be parallel. Joints in paving areas shall be spaced not more than 15 meters (50 ft). Reinforcing Steel: Reinforcing Steel shall not extend through joints. Dowels shall be bonded on only one side of the joint. Water stop shall extend through the joint whenever required. Sealer Application: Non-process Areas: Sealer shall be applied as per the manufacturers recommendations. Process Areas: Joint surfaces shall be thoroughly cleaned to remove curing compounds, laitance, sand and dust etc.

Concrete Works

Page 9 of 14

MACO-QCCP-005


A plastic foam backer shall be inserted in to the joint to provide a depth as per the manufacturers recommendations. Sealer shall be mixed and applied as per the manufacturers recommendations.

6 6.1

INSPECTION AND TESTING: Services of client approved third party testing agency shall be utilized for testing. Perform all tests and inspection in accordance with the client specifications and ITPs.

6.2

6.3 Independent Testing Laboratory shall be employed to perform field and laboratory testing which shall include compressive tests of molded concrete cylinder tests, slump, unit weight, air content (where air entrapment is required) and fresh concrete temperature. The minimum required number of concrete tests cylinders for strength tests shall be 3, for 3,7 and 28 days.

7 7.1

DOCUMENTATION Concrete Work Checklist QCCP-005-01-CW QCCP-005-02-CW QCCP-005-03-CW

7.2 Concrete Request Form 7.3 7.4 Concrete Slump Test Form Concrete Compressive Strength Test Form

QCCP-005-04-CW

Concrete Works

Page 10 of 14

MACO-QCCP-005


CONCRETE POURING CHECKLIST QCCP-005-01-CW


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3 4 5 6 7 8

Concrete mix shall be as per the client specification or as approved by client representative. Test sample shall be taken as per the client specification and requirement. Set form to the required grade, lines, rigidly braced and secure. Anchor bolt size, type and location. Provide expansion/Contraction joint as shown in the drawing. Locate, place and support reinforcement as per the drawing details and specifications. Ensure proper placement and vibration. Perform concrete finishing as required by the client.

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________MACO SUPERVISOR Proponent REPRESENTATIVE


CONCRETE REQUEST FORMConcrete Works Page 11 of 14 MACO-QCCP-005


QCCP-005-02-CW


Time & Date of Pour: _________________ Project: _______________________

Drawing No: _________________________

CONCRETE TYPE 2000 psi 4000 psi OTHERS 100 125 150 175 200

SLUMP REQUIRED Blind

CONCRETE FOR:

Cable Box/Man Hole Paving Walls Pedestal RCC Structure

SIZE OF FORM WORK NOS. LENGTH BREADTH HEIGHT QUANTITY (M)



Concrete Works

Page 12 of 14

MACO-QCCP-005


SLUMP & TEMPERATURE TEST REPORT QCCP-005-03-CW


Date: Project: Sample No. Tested By:

_______________________ _______________________ _______________________ _______________________

Drawing No: _________________________ Sample By: ___________________________

TEST NO.

TRUCK/TICKET NO.

TIME BATCHED HR.

TIME SAMPLED HR.

MAX. TEMP. 0C

SLUMP

REMARKS

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

______________________ SOURCE OF CONCRETE:MACO SUPERVISOR

___________________________ INDEPENDENT TESTING LAB.Proponent REPRESENTATIVE


Concrete Works

Page 13 of 14

MACO-QCCP-005


COMPRESSIVE TEST REPORT QCCP-005-04-CW


Date: Project: Sample No. Tested By:

_______________________ _______________________ _______________________ _______________________

Drawing No: _________________________ Sample By: ___________________________

TRUCK/TICKET NO.

TIME BATCHED HR.

TIME SAMPLED HR.

AIR CONTENT %

MIX TEMP. 0 C

CURING TEMP. 0C

AIR TEMP. 0 C

SLUMP

AGE(DAYS) DIMENSION SL# mm

TEST DATE AREA mm2 WEIGHT g DENSITY Kg/m3 DIAL KnCOMPRESSIVE STRENGTH

Kg/cm2

Psi

MPa

REMARKS



Kg/cm2

Psi

MPa

REMARKS



Kg/cm2

Psi

MPa

REMARKS

Concrete Works

Page 14 of 14

MACO-QCCP-005


DOCUMENT TITLE:

PROCEDURE FOR: GROUTING WORK


001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Grouting Works

Page 1 of 6

MACO-QCCP-006


GROUTING WORKS1 Scope 1.1 This document covers the installation of: Cement Based, Non-Shrink Grout Epoxy Grout 2 Purpose 2.1 The purpose of this procedure is intended to describe the minimum requirement for structural and Equipment Grouting. 3 References

ASTM C307

Test Method for Tensile Strength of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Absorption of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Static Modulus of Elasticity and Poisons Ratio of Concrete in Compression Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Compressive Strength of ChemicalResistant Mortars, Grouts, and Monolithic Surfacing and Polymer Concrete Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing and Polymer Concrete Test Method for Compressive Creep of Chemical-Resistant Polymer Machinery Grouts

ASTM C413

ASTM C469

ASTM C531

ASTM C579

ASTM C580

ASTM C4318

Grouting Works

Page 2 of 6

MACO-QCCP-006


Royal Commission Standards:

GES-013-56

Grouting of Foundation

4

Materials: 4.1 General Requirements: 4.1.1 Cement Based Non-Shrink Grout and Epoxy Grout for Structural and Equipment Grouting shall be as per Royal Commission for Jubail & Yanbu specifications. 4.1.2 Submit manufacturers catalogue to Royal Commission for Jubail & Yanbu representative for approval before placing order for materials. 4.1.3 Resin component shall consist of premeasured, prepackaged, solvent free, epoxy resin specifically formulated for the used grout system. 4.1.4 The hardener component shall consist of a premeasured, prepackaged liquid specifically formulated to produce the specified final properties when mixed with the other component. 4.1.5 The aggregate shall be premeasured, prepackaged blend of inert, inorganic fillers, such as silica, designed specifically to provide the proper flow, handling and physical properties required for the grout product. 4.2 Handling: 4.2.1 Deliver all materials such as resin, hardening component and other admixture to the job site in original containers. 4.2.2 Keep stored material covered and protected.

5

Procedure 5.1 General: 5.1.1 All grouting work shall be done as per the drawing details and Royal Commission for Jubail & Yanbu Specifications.

Grouting Works

Page 3 of 6

MACO-QCCP-006


5.1.2 Epoxy grout shall be installed as per the manufacturers data sheet. 5.1.3 The epoxy grout manufacturers recommendations on maximum depth of pour and length to width ratio shall be followed. 5.1.4 If the grout pour is 100 mm or deeper, the grout manufacturer recommendation for installing reinforcement rebar shall be followed. 5.1.5 Safety requirements specified in the grout manufacturers data sheets shall be followed while application of grout system. 5.1.6 The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations. 5.1.7 When type of grout is not specified by Royal Commission for Jubail & Yanbu, or by the equipment Manufacturer, Cementitious grout shall be used for any of the following: i) For Rotating Equipment that satisfies all of these requirement: Driver horsepower less than 500 (373KW). 3600 RPM or less. Combined weight of machine, driver and base plate up to 2,200 Kg. (5,000 Lbs.) ii) Grouting for structural base plates, anchor bolts, columns and precast members, i.e. wall panels beams etc.

5.1.8 When type of grout is not specified by Royal Commission for Jubail & Yanbu or by the equipment manufacturer, epoxy grout shall be used for any of the following: Equipment with driver horsepower 500 (373 Kw). Equipment with speed greater than 3600 RPM. Equipment that has a combined weight (Machine, driver and base plate) of greater than 2,270 Kg. (5000 Lbs.). All reciprocating machinery with driver horsepower greater than 50 (37KW). 5.1.9 Cementitious grout shall be cured with potable water for a minimum period of seven days.

6

INSPECTION AND TESTING:

Grouting Works

Page 4 of 6

MACO-QCCP-006


6.1 Ensure grouting is as per the drawing details and specifications. 6.2 Follow the maximum depth of pour and length to width ratio is as per manufacturers recommendations. 6.3 Follow the safety requirements specified in the grout manufacturers data sheets. 6.4 If the grout pour is 100mm or deeper, install reinforcement as per manufacturers recommendations. 6.5 The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations.

7 7.1

DOCUMENTATION Grouting Checklist QCCP-006-01-GW

Grouting Works

Page 5 of 6

MACO-QCCP-006


GROUTING CHECKLIST QCCP-006-01-CW


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2

3

4

Ensure grouting is as per the drawing details and Specifications. Follow the maximum depth of pour and length to width ratio is as per manufacturers recommendations. If the grout pour is 100mm or deeper, install reinforcement as per manufacturer recommendation. The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations.

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SUPERVISOR



Grouting Works

Page 6 of 6

MACO-QCCP-006


DOCUMENT TITLE:

PROCEDURE FOR: PROTECTIVE COATING FOR BURIED CONCRETE


001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Protective Coating for Buried Concrete

Page 1 of 5

MACO-QCCP-007


PROTECTIVE COATING FOR BURIED CONCRETE1 Scope: 1.1 This section covers the requirement for materials and application procedure for the following works: Surface preparations for buried concrete surfaces. Coating application for buried concrete surfaces. 2 Purpose: 2.1 This procedure is intended to describe the minimum requirements for surface preparation, Coating application for Buried concrete surfaces. 3 References and Standards:

ASTM D 4263

Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method. Standard Test Method for Indicating Oil or Water in Compressed Air. Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers. Standard Test Method for Measuring Humidity with a Psychrometer

ASTM D 4285

ASTM D 4541

ASTM E 337

Royal Commission Standards:

09874

Protective Coating and Lining System

4

Materials: 4.1 General Requirements: Client approved Coating system specifications or equivalent shall be used.


Page 2 of 5

MACO-QCCP-007


4.2

Paint manufacturers: Unless otherwise specified, manufacturer mentioned below shall be preferred. 4.2.1 Hempel Industrial Coatings. P.O. Box 1077 Dammam 4.2.2 Sigma Paints P.O. Box 7509 Dammam 4.2.3 Saudi Industrial Paint Co. P.O. Box 2549 Riyadh 4.2.4 Arabian Danish Co. Ltd. 4.2.5 Jotun Saudia Co. Ltd.

5 5.1

Procedure: Preparation of Surface: 5.1.1 New concrete shall be allowed to cure for a minimum of 7 days prior to coating or as per client requirement. 5.1.2 Perform preparation and cleaning procedures in accordance with paint manufacturers instructions. 5.1.3 For old concrete surface remove oil and greases by mechanical cleaning. 5.1.4 For old concrete surface remove all loose concrete, sealants and ols coating by abrasive blasting. 5.1.5 In the case of coating for old concrete surfaces any cracks found should be prepared as per the concrete repairing procedure. 5.1.6 Expansion and construction joints, if they are to be removed, be cleaned out and masked off prior to coating. If they are not to be removed, then they must be masked off. When all coating is complete, remove the masking and replace with new sealant as required. 5.2 Application: 5.2.1 All filling and coating must be done after sealing. 5.2.2 All below grade concrete surfaces (except the bottom) shall be coated with Bitumastic 300M by Kop-Coat. The coating shall be applied per the manufacturers instructions after the concrete is a minimum of


Page 3 of 5

MACO-QCCP-007


seven days old. The dry film thickness of the coating shall be a minimum of 0.4 mm (16 mils). Coating of vertical surfaces shall extend to 150 mm (6 inches) above grade. 5.2.3 Finishing coats shall be applied according to the manufacturers data sheet, taking into consideration the spreading rate requirement. 5.2.4 Any visual pin holes and cracks shall be repaired. 5.2.5 Comply with the recommendations of the product time gap between succeeding coatings. 5.2.6 Keep brushes and spraying equipment, clean, dry, and free from contaminants. 5.2.7 Keep brushes and spraying equipment suitable for the finish required. 5.2.8 Do not apply additional coats until the previous completed coat has been approved by the client representative. 5.2.9 Provide wet paint signs required to protect newly-painted finishes.

6

INSPECTION AND TESTING: 6.1 Inspection and Testing shall be performed in accordance with ITP and client specifications.

7 7.1

DOCUMENTATION Protective Coating for Buried Concrete Checklist QCCP-007-01-BC


Page 4 of 5

MACO-QCCP-007


PROTECTIVE COATING FOR BURIED CONCRETE CHECKLIST QCCP-007-01-BC


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3

Only approved products shall be used. Perform preparation and cleaning procedures in accordance with paint manufacturers instructions. Examine surfaces scheduled to receive paint and finishes for conditions that will adversely affect execution. Protect all the hardware accessories, machined surfaces, plates etc., prior to surface preparation and painting operation. For old concrete surface, remove all loose concrete, oil, grease and other contaminants sealants and old coating. Expansion and construction joints, if they are to be removed be cleaned out and masked off prior to coating. Cracks and holes shall be repaired as per old concrete repairing procedure. Previous completed coat has been approved.

4 5 6 7 8




Page 5 of 5

MACO-QCCP-007


DOCUMENT TITLE:

PROCEDURE FOR: WATERPROOFING, CAULKING AND SEALING


001 ISSUE NO.

04/09/09 ISSUE DATE


APT PREPARED BY

GJR CHECKED BY

NZ APPROVED BY

Waterproofing, Caulking and Sealing

Page 1 of 6

MACO-QCCP-008


WATERPROOFING, CAULKING AND SEALING1 Scope: 1.1 This section covers installation of: Water Proofing. Caulking and Sealing. 2 Purpose: 2.1 This procedure is intended to describe the minimum requirements for water proofing system. 3 References and Standards:

ASTM C 156

Test Method for Water Retention by Concrete Curing Materials Standard Specification for Elastomeric Joint Sealant Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers. Test Method for Water Vapor Transmission of Materials

ASTM C 920 ASTM E 96

ASTM E 337

Royal Commission Standards: 07110 Membrane Water Proofing of Underground Concrete Structures

4

Materials: 4.1 General Requirements: 4.1.1 Waterproofing: Membrane shall be preformed, cold applied, self adhesive, laminated sheet membrane or as per the client specifications.


Page 2 of 6

MACO-QCCP-008


4.1.2 Caulking: The compound shall be elastomeric, single or multi-component, non-sag, paintable, and have zero moisture/vapor permeability or as per the client specification. 4.1.3 A ready mixed sealant shall have a consistency suitable for easy mixing with a light hand mixer and easy application by a manual or an air operated gun in a temperature range of 50C to 500C or as per the client specifications. 4.1.4 If required, Manufacturers approved primer shall be provided with the sealant. 4.1.5 Bound Breakers: Polyethylene tapes or as recommended by the sealant manufacturer or as per the client specifications. 4.1.6 Vapor Barrier: 8-Mil polyethylene sheeting, having an ASTM E 96 vapor permanence not exceeding 0.50 per m and having ASTM C 156 loss water not exceeding 0.055 g/cm2 of structure or as per the client specifications. 4.1.7 Vapor Barrier Joint Sealant: Hot or cold applied mastic or plastic cement provided by sheeting manufacturer or as per the client specifications. 4.2 Manufacturers: Manufacturer shall be as per the client specifications. Unless otherwise specified, manufacturer mentioned below shall be preferred. 4.2.1 Fosam Company Ltd. Dammam 4.2.2 Saudi Industrial Company Ltd. Dammam 4.3 Handling: 4.3.1 Deliver materials in original, unopened packages bearing name of the manufacturer and product identification. 4.3.2 Store materials above the ground, under covered area. 5 Procedure: 5.1 General: 5.1.1 Waterproofing, Caulking and Sealing shall be done as indicated in the drawing details and client specifications.Waterproofing, Caulking and Sealing Page 3 of 6 MACO-QCCP-008


5.1.2 Unless otherwise indicated in general use: Sealants in Joints exposed to exterior. Caulking in joints exposed to interior. Caulk and seal joints between frames in masonry opening and the masonry in or against which they are set. 5.2 Preparation: 5.2.1 Waterproofing: Ensure the surfaces are clean, dry and free from dust and dirt, and otherwise prepared as recommended by the material manufacturer. 5.2.2 Caulking and Sealant: Ensure that surfaces and joint cavities are clean, dry and free from loose particles, oil, grease, asphalt tar, dirt, rust and other materials that may result in the loss of bond. 5.3 Application: 5.3.1 Caulking: Apply caulking as recommended by the sealant manufacturer or as per the client specifications. 5.3.2 Tool caulking smooth, free from wrinkles and sufficiently convex to result in flush finish joint when dry. 5.3.3 Sealant: Apply in accordance with manufacturers printed instructions regarding mixing, surface preparation, application life and application procedure. 5.3.4 Prime concrete, masonry, wood and other porous surface. 5.3.5 Mask finish surfaces on both sides of the joint cavities to protect from sealant smears. Remove masking after joints are sealed and tooled. 5.3.6 Fluid Applied Waterproofing: Apply in accordance with manufacturers printed installation specifications. Thin first coat.


Page 4 of 6

MACO-QCCP-008


Apply second coat to produce a minimum dry fill thickness of 10 mils. 5.3.7 Vapor Barrier: Place polyethylene sheeting as indicated in drawing. Lap sheet 150 mm (6 in.) with the top sheet placed in the direction of concrete placement. Turn sheeting up at the walls and seal all lap joints.

6 6.1

INSPECTION AND TESTING: Perform inspection and testing in accordance with client approved ITP and client specifications.

7 7.1

DOCUMENTATION Water Proofing, Caulking & Sealing Checklist QCCP-008-01-WP


Page 5 of 6

MACO-QCCP-008


WATERPROOFING, CAULKING AND SEALING CHECKLIST QCCP-008-01-WP


Reference: Project:

_______________________ _______________________

Drawing No: _________________________

S. NO.

INSPECTION POINTS

ACCEPT

REJECT

N/A

1 2 3

Only approved products shall be used.

Documents

Complete Quality Manual Vol 2 Rev. 2010