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DOC. NO. KOC-C-026 Page 1 of 38 REV. 1

KUWAIT OIL COMPANY (K.S.C.). .

STANDARDS PUBLICATION

KOCSTANDARD

FOR

STORAGE TANK FOUNDATION

DOC. NO. KOC-C-026

STANDARDS DIVISION

KOC STANDARD

FOR

STORAGE TANK FOUNDATION

DOC. NO. KOC-C-026 (FORMERLY 0 1 5 - SH -1001)

ISSUING AUTHORITY:

STANDARDS DIVISION L

DOC. NO. KOC-C-026 I Page 3 of 38 I REV. 1

TABLE OF CONTENTS

PAGE NO.

FOREWORD

SCOPE

APPLICATION

TERMINOLOGY

REFERENCE STANDARDS AND CODES

ENVIORNMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

SITE & SUB-SURFACE INFORMATION

TECHNICAL REQUIREMENTS

FOUNDATION DESIGN

MATERIAL REQUIREMENTS

CONSTRUCTION REQUIREMENTS

EARTH FOUNDATION WlTH CONCRETE RlNG WALL

EARTH FOUNDATION WITHOUT CONCRETE RlNG WALL

REPAIR OF DEFECTS 1 DAMAGES

INSPECTION AND TESTING

QUALITY ASSURANCE

DOCUMENTATION

APPENDICES

APPENDIX-I : WP. EARTH FOUNDATION OF TANK WlTH CONCRETE RlNG WALL

APPENDIX-II : TYP. EARTH FOUNDATION OF TANK WlTH CONCRETE RlNG WALL ( WITH EMBEDDED C. P SYSTEM )

b

DOC. NO. KOC-C-026 I Page 4 of 38 I REV. 1

APPENDIX-Ill : TYP. EARTH FOUNDATION OF TANK WITHOUT CONCRETE WALL RING

APPENDIX-IV : SITE RECORD FOR FOUNDATION WORK

FOREWORD

This document " KOC Standard for Storage Tank Foundation " is intended to address the need for consistent and practical requirements for design, material selection and construction of a sound foundation with a view to maintaining the integrity and service life of field erected storage tanks on grade.

The types of foundation addressed in this Standard are limited to earth foundations with or without concrete ring walls which are generally used for aboveground, vertical storage tanks in KOC. Smaller tanks on concrete foundations or on elevated framed structures are intended to be covered by the established design procedures used in the industries in accordance with International 1 National standards (BS, ACI, AlSC etc.).

This Standard has been approved by the Standards Technical Committee and Standards Division for use throughout the corporate engineering and operational functions of Kuwait Oil Company.

This Standard sets out to achieve the following objectives :-

a) To establish the basic technical requirements pertaining to the design, material selection and construction of foundations for aboveground, vertical steel storage tanks.

b) To provide general technical guidance for developing project specifications in order to achieve reliability, quality and safety in an economical manner.

C) To set out clear requirements to monitor compliance in design, material and construction of tank foundations with a contract.

d) To maintain the KOC requirements of safety and environmental protection established by KOC regulations and procedures.

Feedback as well as any comments or suggestions derived from the application of this Standard at any stage of conceptual design, engineering, purchase or field construction are invited and should be directed to :

Supdt. Standards Division (Chairman, Standards Technical Committee) Engineering Group, K.0.C P.O.Box- 9758, Ahmadi 61 008, State of Kuwait

The preparation of this Standard is acknowledged to the Task Force (TF-CIVJO1 ) comprising of the following members:-

Mr. S. Kumar (Standards Div.) Team Leader /Author Mr. Javaid Masood (Engg. Design Div.) Member / Author (Part) Mr. Khalid Al-Sayed (Maint. Project Div.) Member

Page 6 of 38 I REV. 1 I

SCOPE

This Standard specifies the minimum basic requirements for the design, materials and workmanship related to the following types of Foundation for aboveground, vertical, sloping bottomed Steel Storage Tanks at the KOC facilities within Kuwait :- -

a) Earth Foundation with Concrete Ring Wall

b) Earth Foundation without Concrete Ring Wall.

This Standard covers the extent of work as described herein and includes, but not limited to, design, excavation, reinforced concrete construction, backfilling, compaction of fill materials, surface protective layers, inspection, testing and quality control involved in the works.

This Standard does not address the other aspects of Site work such as demolition, site clearance, borrow pit, excavation, filling, hauling, compaction, disposal etc. which are specifically covered under KOC standard for materials and workmanship - " Site Preparation and Earthworks " ( KOC-C-005 ).

However, this Standard does not specify the actual extent of foundation work which shall be in compliance with the relevant contractual requirements specified in Scope of Work , Technical Specifications and Drawings.

APPLICATION

The design, materials, construction and testing for any work related to the specified type of storage tank foundation shall conform to the requirements of this Standard and the reference standards / codes mentioned herein.

The allowable soil loading and the exact type of subsurface construction to be used must be decided for each tank or group of tanks after careful consideration of design and ground conditions prior to the application of this Standard.

Any exceptions or deviations ftom this Standard, along with their merits and justification, shall be brought to the attention of KOC Controlling Department for their review, consideration and amendment by Standards Division ( if required ).

Compliance with this KOC Standard does not of itself confer immunity from legal or statutory obligations.

TERMINOLOGY

For the purposes of this Standard, the following definiCans apply.

3.1.1 designer

person or persons from KOC or firm / company approved'by KOC who are undertaking the design of the tank foundation work.

contractor

person or persons, firm or company, approved by KOC, who are undertaking the construction work covered by this Standard.

gatch

local name of a type of calcareous soil.

NOTE This, as a fine to medium well graded granular material, exhibits good cementing properties under compaction. It is widely used in Kuwait as a major filling material.

suitable material

all materials such as gravels, graded sands, silt and non-plastic clay.

NOTE Sizes nor larger than 50 mm for fill / backfill in accordance with KOC Standard KOC-C- 005 as to compaction and soil classification.

unsuitable material

perishable or combustible material, peat, muck, slurry, rocks or any buried debris, highly sensitive plastic clay, expansive clay.

optimum moisture content ( OMC 1

moisture content expressed as a percentage of dry mass at which a specified amount of compaction will produce the maximum dry density.

compaction

process of packing soil particles more closely together by rolling or by other mechanical means, thus increasing the dry density of the soil as a consequence of removal of air from the voids between particles.

asphalt cement

a fluxed or unfluxed asphalt specially prepared as to quality and consistency for direct use in the construction of bituminous pavements, and having a penetration at 25°C (77°F) varying between 5 to 300, under a load of 100 grams applied for 5 seconds.

penetration grade

consistency of a bituminous material expressed as the distance in tenths of a millimetre (0.1 mm) that a standard needle penetrates vertically a sample of the material under specified conditions of loading, time and temperature.

NOTE For exemple, ssphelt grade 70 expresses ?he consistency when tested at 25C, a standard needle weighing 8 total of 100 grams penetnrtes 8 material sample in 5 seconds a maximum distance of 7 mm or 70 tenths of a mm.

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Abbreviations --

KOC Kuwait Oil Company ( K.S.C. 1

HSE Health, Safety and Environment

OFT Dry Film Thickness

REFERENCE STANDARDS AND CODES

Conflicts

In the event of conflict between this Standard and the standards / codes referenced herein, or other purchase or contractual requirements, the most stringent requirement shall apply.

List of Standards and Codes

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

Standards and Codes

ACI 31 5

ACI 318M

API 650

ASCE

ASTM A61 5

ASTM C33

ASTM C39

ASTM C88

ASTM C l s l

ASTM C136

ASTM C150

ASTM D5

ASTM 0242

Details and Detailing of Concrete Reinforcement

Building Code Requirements for Reinforced Concrete

Welded Steel Tanks for Oil Storage

Guidelines for Seismic Evaluation and Design of Petrochemical Facilities by Task Committee

Specification for Deformed and Plain Billet Steel Bars for Concrete Reinforcement

Specification for Concrete Aggregates

Test Method for Compressive Strength of Cylindrical Concrete Specimens

Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

Test Method for Resistance to Degradation of Small-Size Coarse Aggregate b y Abrasion and Impact in the Los Angeles Machine

Method of Sieve Analysis of Fine and Coarse Aggregates

Specification for Portland Cement

Test Method for Penetration of Bituminous Materials

Specification for Mineral Filler for Bituminous Paving Mixtures

DOC. NO. KOC-C-026 I Page 9 of 38 I REV. 1

ASTM D546

ASTM D692

ASTM D946

ASTM D 1073

ASTM Dl075

ASTM D1 556

ASTM D1 557

ASTM Dl559

ASTM 01751

ASTM 021 72

ASTM D35 1 5

BS 410

BS 812

BS 882

BS 1377

BS 1881

BS 2654

BS 4449

BS 4466

BS 5075 (Part 1)

BS 8004

Test Method for Sieve Analysis of Mineral Filler for Road and Paving Materials

Specification for Coarse Aggregate for Bituminous Paving Mixers

Specification for Penetration-Graded Asphalt Cement for Use in Pavement Construction

Specification for Fine Aggregate for Bituminous Paving Mixtures

Test Method for Effect of Water on Compressive Strength of Compacted Bituminous Mixtures

Test Method for Density of Soil In Place by the Sand Cone Method

Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort

Test Method for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus

Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction ( Non-extruding and Resilient Bituminous Types )

Test Methods for Quantitative Extraction of Bituminous Paving Mixtures

Specification for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

Specification for Test Sieve

Methods of Testing Aggregates

Specification of Aggregates from Natural Sources for Concrete

Methods of Test for Soils for Civil Engineering Purposes

Testing of Concrete

Specification for Manufacture of Vertical Steel Welded Non- Refrigerated Storage Tanks with Butt-Welded Shells for the Petroleum Industry

Specification for Carbon Steel Bars for the Reinforcement

Specification for Scheduling, Dimensioning, Bending and Cutting of

Concrete Admixtures - Specification for Accelerating Admixtures, Retarding Admixtures and Water Reducing Admixtures

Code of Practice for Foundations

BS 8110 Structural Use Concrete - Code of Practice for Design and (Part 1) Construction

KOC Standards

KOC-C-001 KOC Standard for Basic Civil Engineering Design Data

KOC-C-005 KOC Standard for Materials and Workmanship - Site Preparation and Earthworks

KOC-C-006 KOC Standard for Materials and Workmanship - Concrete Works

KOC-C-033 KOC Standard for Materials and Workmanship - Bund Wall for Storage Tanks

KOC-G-007 KOC Standard for Basic Design Data

KOC-1-026 KOC Recommended Practice for External Cathodic Protection for New Steel Tank Bottoms

KOC-MV-007 KOC Standard for Field Erected Storage Tanks

5.0 ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Refer to KOC Standard for Basic Design Data (KOC-G-007) which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

6.0 HEALTH, SAFETY AND ENVIRONMENT

6.1 The contractor shall employ the necessary health and safety procedures to protect personnel and surrounding environment during Site preparation end other on-site field works.

6.2 All relevant safety requirements of the KOC Fire & Safety Regulations and the KOC HSE policy shall be adhered to while performing the works within KOC areas.

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SITE 81 SUB-SURFACE INFORMATION

General

The topography of a Site shall be assessed from the area contour maps on the basis of a recently conducted topographical survey of the actual tank Site and its adjoining areas.

For ease of reference, the Site formation level shall generally be considered as Site grade level equal to EL1 00.00 m. The relationship of this level with the Mina Ahmadi Construction Datum (MACD) shall be established by the designer /contractor and shown on all major layout drawings.

The Site co-ordinates ( Northing & Easting ) shall be established in Universal Transverse Mercator (UTM) Grid, Zone 38, World Geodetic System (WGS) at the time of topographical survey and shall be verified further by the contractor prior to commencement of any work.

Sub-surface Conditions

KOC shall conduct a geotechnical investigation at any tank site to determine the subsurface conditions and its suitability for the proposed tank sizes. The investigation should address, among other information, the bearing capacity of the soil, anticipated settlements - immediate, long-term and differential settlements.

However, as the settlement calculations are of limited accuracy, the tank manufacturer I contractor shall use the information and recommendations from this KOC report as guidance only and is responsible to make his own interpretations about the site conditions by carrying out any additional or supplementary geotechnical exploration, if deemed to be necessary. Any additional exploration shall be conducted with the minimum three ( 3 boreholes at 120' under the tank area(s).

The subgrade must be capable of supporting the load of tank and its contents. The total and peripheral differential settlements shall be assessed not to strain the connecting piping or produce gauging inaccuracies and shall be within the acceptable tolerances for the tank shell and bottom.

In case subgrade supporting the foundation is weak and inadequate to carry the load of the filled tank without excessive uniform settlement (1 50 mm or more), one or more of the following special measures should be considered for improving the support conditions :-

a) Removal and replacement of unsuitable material below the foundation by the suitable compacted fill material.

b) Densification of soft or ioose materials by vibroflotation, dynamic compaction or preloading with an overburden of other material.

C) Sub-soil drainage by stone columns or sand drains with or without preloading .

d) Stabilization by chemical or grout injection methods.

NOTE Spsclbl technques of grorrndh,prowmant nslatd to items (bj to (dl above are outside the mope of this Stamhi and dm1 & dsslY lbpuatdy.

TECHNICAL REQUIREMENTS . . . .

General

The tank foundation shall be designed and installed satisfying the requirements as laid down in this KOC Standard and API 650 for the safe and satisfactory performance of the underlying supporting soil and the foundation system.

Normally, the tank foundations should not be located in Sites on swampy or filled ground, where layers of soft and compressible materials (muck, organic or plastic clay) are below the surface in order to avoid excessive long term settlement problems.

The ultimate bearing capacity of tank foundation shall be determined by a comprehensive stability analysis. The following ranges for factors of safety should be considered for use in foundation design criteria for determining the allowable soil bearing pressures :-

a) From 2.0 to 3.0 against ultimate bearing failure for normal operating conditions.

b) from 1.5 to 2.25 against ultimate bearing failure during hydrostatic testing.

C) from 1.5 to 2.25 against ultimate bearing failure for normal operating condition plus the maximum effect of wind or seismic (if applicable) loads.

However, depending on the actual sub-surface conditions, KOC may use factor of safety outside the above ranges in compliance with the recommendations of the geotechnical specialist.

The permissible settlements 9.g. the maximum allowable design limits for the settlement of the foundation shall be agreed between KOC and the tank manufacturer for the uniform (total) and differential settlement across the bottom and the periphery of the tank.

Considerations affecting the limits of permissible settlement should be given to the following :-

a) The dimensions and aspect ratio (HID) of the tank.

b) Tank types e.g . open roof, fixed roof or floating roof (pontoon type).

C) Effect of cyclic loading on the amount of iong-term ( total ) settlement.

DOC. NO. KOC-C-026 I Page 13 of 38 I REV. 1

d) Type of underlying soil (slow draining, pockets of weak soils).

e) The difference in settlement between the periphery and the centre.

The following permissible range of predicted settlements for tank foundations should be considered as guidance only:

a) 50 mm for uniform (immediate) settlement or 1.5 mm per metre ( 112 inch per 30 ft )for differential settlement during hydrostatic testing of the tank.

b) Maximum differential settlement for floating roof tank not to exceed - 2.8 mm per metre ( 1 inch per 30 ft ) of circumference.

c) Maximum differential settlement for fixed roof tank not to exceed - 50 to 75 mm from edge to centre of foundation or 4.0 mm per metre ( 1.5 inch per 30 ft ) of circumference.

d) 100 - 150 mm for long-term uniform (total) settlement.

e) In case of excessive settlement ( > 150 mm 1, special measures shall be taken to strengthen the supporting soil in conformity with dause 7.2.4 of this Standard.

During hydrostatic and leak testing of tanks in accordance with dause 11.7.5 of KOC- MV-007, adequate level of careful observations and monitoring of foundation behaviour shall be taken to prevent any unexpected and abnormal soil movement which may tend to exceed the specified limit of foundation settlement in the testing procedure.

Subgrade Protection

The subgrade protection from leakage of tank contents ( hydrocarbon, chemicals etc. ) shall be decided by the KOC Controlling Department considering the presence of ground water at shallow depth, hazards of contaminated soil, effectiveness of cathodic protection system and cost involved in providing the system.

However, in view of increasing consciousness of environmental and safety implications . due to leakage of tank contents into the containment space below the tank bottom, API 650 recommends under Appendix I to provide secondary containment barrier such as flexible membrane liner or other suitable system which is not mandatory.

Tank Grades I %

The grade or surface on which a tank bottom will rest should be constructed at least 300 mm above the surrounding ground surface. However, any appreciable settlement of subgrade, when predicted at the design stage, shall be compensated by raising the tank bottom elevation.

In case of oil storage tanks, if the membrane liner within the tank pad is recommended for environmental protection for any oil leakage, the tank grades shall be increased, as required, to accommodate the cathodic protection system below the tank bottoms for the prevention of corrosion.

.. DOC. NO. KOC-C-026 I Page 14 of 38 I REV. 1

8.6.1 Based on the adequacy of subsurface conditions e.g. the load bearing capacity of soil and permissible settlements, the types of tank foundations should be considered for tank sizes (diameter & height) as below unless otherwise specified:-

a) Earth foundation with concrete ring wall for tanks ( Diameter > 35 m & Height 2 15 m 1

b) Earth foundation without concrete ring wall for tanks ( Diameter < 35 m & Height < 15 m

8.6.2 Notwithstanding above, in some situation, the foundations of smaller tanks may be installed with concrete ring wall with the following considerations over the foundation without ring wall :

a) It provides better distribution of the concentrated load of the shell to produce a more nearly uniform soil loading under the tank.

b) It provides a level, solid starting plane for construction of the shell.

c) It provides a better means of levelling the tank grade and is capable of preserving its contour during construction.

d) It retains the fill under the tank bottom and prevents the loss of material from erosion.

e) It acts to minimise moisture under the tank.

However, foundation without concrete ring wall performs well in areas with good soils; and is inexpensive compared to that with concrete ring wall.

9.0 FOUNDATION DESIGN

The tank foundations shall be designed considering the following conditions in accordance with the design loads specified in data sheet(s) of KOC Standard for " Field Erected Storage Tanks " (KOC-MV-007).

9.1.1 Vertical Loading

Dead weights of tank including all attachments end appurtenances plus the full weight of stored product or water whichever is greater shall be accounted.

9.1.2 Horizontal Loading

tiorizontal loads shall be taken due t o wind forces on tank shell, roof and its attachments as well as liquid contents ( empty or full ) at the tank bottom. Seismic condition (if applicable) shall not be combined with wind condition.

1 9-1-3 Sliding Stability

Sliding stability of tank foundation shall be checked due to horizontal loads as -

mentioned above in clause 9.1.2 against soil friction neglecting passive earth pressure. A minimum safety factor of 1.5 shall be taken against sliding.

1 9-1.4 Uplift I Overturning I Anchorage

a) The requirement of tank anchorage due to uplift shall be recommended by the tank manufacturer against overturning instability for wind or seismic conditions in accordance with relevant clauses of API 650 or BS 2654.

b) However, additional vertical load from the overturning moment due to wind or seismic forces shall be considered on the foundation for any unanchored or anchored tanks.

C) If the anchors are necessary, the embedment strength of anchor bolts in the foundation shall be provided to develop the minimum yield strength of the anchor. Hooked anchor or end plates may be used to resist pullout.

1 9.2 Earth Foundation With Concrete Ring Wall

1 9.2.1 General

a) The foundation shall consist of a reinforced concrete (RC) ring wall directly supporting the tank shell and a compacted earth pad below the tank bottom as a inner core.

b) The average unit soil loading under the ring wall shall be designed within the allowable soil bearing capacity and approximately the same as under the confined earth at the same depth to minimise the chance of differential settlements.

1 9.2.2 Concrete Ring Wall

a) The ring wall shall be designed to fully withstand any stresses ( hoop, uplift, bearing, bending, shear, torsion and temperature etc. ) induced by the tank and its contents under the most severe loading conditions (static, dynamic and cyclic). The most critical load combinations including wind or seismic effects and differential settlements that induce the worst stresses within the concrete should be considered.

I b) The design of concrete shall conform to ACI 31 8 or BS 81 1 0.

C) The ring wall shall not be less than 300 mm thick and its bottom shall be founded within the specified bearing strata but not less than 900 mm for tank dia. 2 35m and 600 mm for tank dia. < 35m below the finished grade or natural ground level whichever is lower, subject to the actual site conditions.

d) The centre line diameter of the ring wall shall be equal to the nominal diameter of the tank. However, the centre line may vary, in case it is required to provide anchor bolts or to satisfy soil bearing limits for excessive uplift forces.

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The ring wall shall be reinforced to resist direct hoop tension resulting from the lateral earth pressure on the ring wall inner face. The lateral earth pressure shall be taken at least 50% of the vertical pressure due to liquid contents and soil weight. If granular backfill is used, a lateral earth pressure co-efficient of 30% may be used.

The ring wall shall be reinforced to resist the bending moment resulting from the uniform moment load which shall account for the eccentricities of the applied shell and pressure loads relative to the centroid of the soil pressures due to the liquid pressures on the horizontal projection of the ring wall inside the shell.

Adequate reinforcements shall be provided to resist the bending and torsional moments from lateral and wind or seismic (if applicable) loads.

Reinforcement provided for resisting direct hoop tension for temperature changes and shrinkage shall in no case be less than 0.25 % of the vertical cross-sectional area of the ring wall.

The minimum vertical reinforcements for temperature changes and shrinkage shall be 0.15 % of the horizontal cross-sectional area of the ring wall. Reinforcements shall be provided on both faces of ring wall.

Corner chamfers (50 mm x 50 mm) shall be provided to the outside and inside faces of top of concrete ring wall.

Footing shall be provided below the ring wall when the width of the wall exceeds 450 mm.

9.2.3 Earth Pad Below Tank Bottom

a) Earth pad within the confined area of ring wall below the tank bottom shall be composed of compacted gatch in accordance with KOC Standard KOC-C-005 and shall conform to the tank grade level specified in dause 8.5 of this Standard.

b) The compacted gatch shall be cambered from the tank centre to the tank shell at e minimum slope of 1 :I20 for drainage and shall conform to the tank bottom slope specified in KOC-MV-007.

c) It shall then be overlaid with the successive layers es follows :

i. a stable and permeable layer of 100 mm thick smdqravei mix with gradation as per dause 1 0.2.1 of this Standard.

ii. a final layer of dean washed sand as bearing surface of tank bottom with gradation as per clause 10.2.3 of this Standard. The thickness shall vary from minimum 1OOmm ( for non-embedded CP system ) to maximum 400mm ( for embedded CP system 1.

d) The finished level shall be smooth and free from any irregularities. Details related to the tank bottom shall be informed to the tank manufacturer for the ease of fabrication.

9.2.4 Surface Protective Layers

The surface protective layers shall be provided in conformity with the following materials :-

a) The top surface of concrete ring wall beneath the bottom annular plates of tank shell shall be covered with a 25 mm thick asphalt impregnated board in conformity with ASTM Dl751 or with 25 mm thick non-shrink grout of a proprietary brand as approved by KOC.

b) The outside area of the ring wall shall be covered with a minimum depth of 225 mm compacted gat& and finished with 75 mm thick protective layer of asphaltic concrete as specified in clause 10.3 of this Standard to form a firm shoulder around the tank periphery. Shoulder shall be at least 900 mm wide with gentle slope of 5% and then have a slope of 1:l-112 towards the graded surface.

9.2.5 Cathodic Protection

a) For cathodic protection system embedded below the tank bottom, the total depth given in 9.2.4 (b) shall be increased to minimum 750 mm which shall be verified for adequacy by the designer I contractor.

b) Permanent reference electrodes to monitor the effectiveness of CP system shall be installed within the foundation pad below the tank bottom in accordance with clause 8.1 0 of KOC-L-026.

9.2.6 Leak Detection

To detect any leakage from the tank bottom, 75 mm dia. PVC pipes or equal shall be provided at a spacing not more than 5.0 m c/c around periphery of the foundation and shall be connected to a covered collection pit at suitable location. Plastic mesh screen shall be fixed inside the open end of the pipe.

9.2.7 Membrane Liners (Optional)

Membrane liners, if recommended as per clause 8.4 of this Standard, should be flexible, chemically resistant and suitable to the subgrade soil. Minimum thickness shall be 1000 microns (40 mils) for polyethylene sheet liner.

9.2.8 Refer to Appendix-l for details of earth foundation with concrete ring wall and Appendix4 for details of tank foundation with embedded C.P system.

DOC. NO. KOC-C-026 I Page 18 of 38 I REV. 1

Earth Foundation Without Concrete Ring Wall

General

a) The foundation shall consist of a compacted crushed stone ring wall to support directly the tank shell for better distribution of the concentrated load from the shell and produce more nearly uniform soil loading under the tank. '

b) The earth pad below the tank bottom as a inner core shall be made of layers of well compacted fill of gatch, overlaid with a compacted 100 mm thick sand - gravel layer on top of it and finished with a final layer of 150 mm dean washed sand cushion as bearing surface of tank bottoms .

Tank shell Ring

a) The ring beneath the tank perimeter shall be 1800 mm (6 f t ) wide with tank shell as centre end shall have slopes of 1 : 1-1 I2 on both inside and outside. Bottom shall be founded within the specified bearing strata but not less than 900 mm below the finished grade or natural ground level whichever is lower, subject to the actual site conditions.

b) The ring shall be composed of compacted 25 mm graded crushed stone or gravel with screenings and dean sand.

Earth Pad Below Tank Bottom

The earth pad below the tank bottom shall be provided with the same materials as detailed in clause 9.2.3 of this Standard.

Surface Protective Layers

a) The outside area of the ring wall shall be finished with a 75 mm thick protective layer of asphaltic concrete as specified in clause 10.3 of this Standard to form a firm shoulder around the tank periphery. This protective layer shall extend from the outer toe of the slope to at least 900 mm inside of the tank perimeter.

b) 25 mm thick asphalt impregnated board in conformity with ASTM D l 751 or 25 mm thick non-shrink grout of a proprietary brand as approved by KOC shall be provided below the bottom annular plate of the tank shell to cover the full width of the plate.

Similar details shall be followed as given in clauses from 9.2.5 to 9.2.7 of this Standard for CP system embedded below the tank bottoms, pipes for leak detection end membrane liners.

Refer to Appendix-Ill for details of earth foundation wittrout concrete ring wall.

DOC. NO. KOC-C-026

MATERIAL REQUIREMENTS

Fill Material

Gatch t o be used for construction of storage tank foundation(s) and grading of outer areas over the general formation level indicated on the drawings / specifications shall be borrowed from KOC approved borrow pits and shall comply with all the requirements specified in clause 7.0 & 8.0 of KOC Standard KOC-C-005.

Materials that do not conform t o the requirements of clause 7.2 of KOC Standard KOC-C-005 shall be considered unacceptable, removed from the Site and replaced with gatch or approved suitable soil in accordance with clause 7.0 of KOC Standard KOC-C-005.

Sand-Gravel Mix

The sand-gravel layer shall consist of crushed mineral aggregates or natural mineral aggregates in conformity with the gradation of coarse t o fine percentages given in Table I.

Table I : Particle Size Grading

Coarse Aggregate

a) Coarse aggregate retained on the sieve size 4.75 mm crushed stone, crushed gravel or natural gravel. The aggregate shall be 25 mm.

( No. 4 ) shall be made of maximum size of coarse

b) Coarse aggregate shall be hard, durable and free from organic matter, silt, clay and any other deleterious materials.

c) Coarse aggregate shall conform t o the various requirements, when tested, in accordance with ASTM C131 and BS 81 2; and when subjected t o 5 cycles of the soundness test as per ASTM C88 shall have a weighted loss not more than 5 % when magnesium sulphate is used.

f ine Aggregate . -

a) Fine aggregate passing the sieve size 4.75 m m ( No. 4 ) shall consist of graded natural sand and 1 or crushed sand conforming t o BS 882, Table 4,-Grading C or M.

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b) Fine aggregate shall be clean, free from organic matter, silt, clay and other detrimental and deleterious materials. The ratio of fine aggregate passing the- sieve size 75 pm ( No. 200 ) shall not be more than 213 of the amount passing the sieve size 4.75 mm ( No. 4 1.

C) Fine aggregate shall be washed as necessary, w h k tested, t o comply with the requirements in accordance with BS 812 and in addition,. shall satisfy the following chemical analysis :

I. Sulphates as SO3 < 250 ppm (0.025%)

ii. Chlorides as CI < 50 ppm (0.005%)

d) The material passing the 425 pm ( No. 40 ) sieve shall have a liquid limit less than 35 and a plasticity index not more than 6.

Wherever the gradation does not conform to the limits specified, the layer shall be scarified, removed andlor reworked as directed by KOC t o provide the material mix within the above limits.

As~halt ic Concrete

a) The asphaltic concrete shall be composed of hot mixing of crushed mineral aggregate, natural sand, mineral filler of limestone cement and asphalt cement in

conformity with clauses 10.3.2, 10.3.3, 10.3.4 and 10.3.5 of this Standard.

b) The asphaltic concrete mix should be selected from the recommended grading requirements for coarse and fine aggregate from ASTM D l 073 with mineral filler and asphalt cement as binder in the approximate quantities by weight of total aggregate as follows:

I. Mineral Filler - 5 % f 1 %

ii. Asphalt Cement - 7 % f 0.5 %

Coarse Aggregate

a) Coarse aggregate retained on the No. 8 (2.36 mm) sieve shall consist of crushed natural stone and gravel. Coarse particles shall be cubic and angular in shape and shall not be thin, flaky or elongated.

b) Coarse aggregate shall be clean and free from organic matter, sand, silt, clay and clay and other detrimental or deleterious matter and shall have particles not less than 80% by weight with at least one fractured face.

C) Coarse aggregate shall be sound, when the particles subjected to the five ( 5 ) cycles of the soundness test in accordance with ASTM C88, shall have the weighted loss not more than 12 % when sodium sulphate is used or 18 % when magnesium sulphate is used.

DOC. NO. KOC-C-026 I Page 21 of 38 I REV. 1

1 0.3.3 Fine Aggregate

a) Fine aggregate passing the No. 8 ( 2.36 mm ) sieve shall consist of graded natural sand andlor crushed sand conforming to ASTM Dl 073 Grading 2.

b) Sand shall be clean, free from organic matter, silt, clay and other injurious or deleterious materials and shall be washed as necessary. Sand shall be free from the chemicals such as sulphate and chloride and shall satisfy the requirements in accordance with BS 81 2.

C) Fine aggregate, when subjected to the five ( 5 cycles of the soundness test in accordance with ASTM C88, shall have weighted loss not more than 15% when sodium sulphate is used or 20% when magnesium sulphate is used.

d) The fraction of fine aggregate passing the No. 40 ( 425 pm sieve shall have a plasticity index not more than 4; and the fraction passing the No 200 ( 75 pm ) sieve shall not have fines more than 5 % by weight.

1 0.3.4 Mineral Filler

a) Mineral filler shall consist of finely ground particles of limestone cement in accordance with ASTM D242 and shall be thoroughly dry and free from lumps.

b) Mineral filler shall be tested to comply with ASTM D546 for sieve analysis and shall be graded per ASTM D242 within the limits given in Table II :-

Table II : Physical Requirements of Mineral Filler

c) Cement to be used as mineral filler shall meet the requirements of Type I, II, or V in accordance with ASTM C150.

1 0.3.5 Asphalt Cement

a) Asphalt cement shall be 60-70 Penetration Grade and shall satisfy the requirements in accordance with ASTM D946 8s given in Table Ill :-

DOC. NO. KOC-C-026 I Page 22 of 38 I REV. 1

m e Ill : Requirements for Asphaft Cemnt (60-70 Grade)

I 1 thin-film oven test I I 1 Note 1- N ductility at 25 "1: ( 77 51 is less than 100cm, material will be accepted 17

ductility st 15.5 S: ( 60 F 1 is lOOcm at the pull rete of 6 cm / min.

b) Asphalt cement shall be uniform in character and shall not foam when heated to 175 O C ( 347 O F 1.

The selected materials of in-situ concrete for ring wall construction shall comply with the following clauses 10.4.2 to 10.4.7.

Cement

a) Unless otherwise mentioned, Portland Cement conforming to ASTM C150 Type II or V shall be used.

b) Only a single brand of cement shall be used throughout the work; change of brand shall be subject to KOC approval.

Aggregates

Aggregates shall comply with BS 882 or ASTM C33 and conform to the following :-

a) It shall be dean, free from oil, grease or any contamination; hard, sound and mixture of well graded coarse and fine partides.

b) All partides shall pass s 20 mm ( 314 in ) BS 41 0 sieve sue and the fineness modulus of fine aggregates shall be neither less than 2.3 nor more than 3.1.

l i '

c) Fine aggregates shall be free from organic / inorganic impurities and shall not contain other deleterious substances more than 5 % by weight.

C) The aggregates for in-situ concrete shall be composed of maximum 20mm single- sized coarse aggregates in accordance with Table 3 of BS 882 with fine aggregates conforming to Grading C or M of Table 4 of BS 882.

e) All aggregates shall meet the testing requirements in accordance with BS 81 2, ASTM C88 and ASTM C131.

Reinforcement

Reinforcement shall be new, uncoated, free from rust, scale, salts or any deleterious material which can reduce or destroy bond with the concrete. It shall comply with the specified grades as follows:-

a) High yield deformed bars to be used as main reinforcements shall have the minimum specified characteristic strength of 460 N / mm2 in accordance with BS 4449 or Grade 60 with a specified yield of 414 N / mm2 in accordance with ASTM A61 5.

b) Plain, round mild steel bars to be used as stirrups, ties and links shall have the minimum specified characteristic strength of 250 N / mm2 in accordance with BS 4449 or Grade 40 with a specified yield of 414 N / mm2 in accordance with ASTM A61 5.

C) Lap reinforcement splices shall be used to develop full strength complying with ACI 31 5 or BS 4466.

Admixtures

Normal water reducing admixtures as defined in BS 5075 shall be added to in-situ concrete to maintain sufficient workability at the minimum water / cement ratio. The type of admixture shall be subject to KOC approval and the dosage and mixing shall be strictly in compliance with the instructions of the manufacturer. Under no I circumstances, shall admixtures containing chlorides or other corrosive agents be used.

Water

Only clean and clear water from potable supply system shall be used.

Concrete Mix

The in-situ concrete shall comply with BS 81 10 and shall have a minimum cement content of 370 kg/m3 for structural concrete. The minimum characteristic strength of structural concrete ( Grade 20 1 at 28 days shall be 20 ~ / m m ~ . The minimum concrete grade 15 shall be used for blinding concrete.

Supply end Storage of Materials

All materials shall be adequately protected against any contamination and damages and from the weather during 'loading, transportation, unloading and storage. Bagged materials shall not be set directly on the ground and shall be kept under cover and dry.

Materials that do not conform to the requirements of this Standard and the reference standards / codes shall be rejected and removed immediately from the place of work as directed by KOC.

DOC. NO. KOC-C-026 I Page 24 of 38 I REV. 1

CONSTRUCTION REQUIREMENTS

The contractor shall provide all materials in conformity with dause 10.0 of this Standard ; equipment, tool$ and experienced manpower necessary for carrying out the work.

All equipment, tools and machines used by the contractor in the proper execution of the work shall be subject to KOC approval and shall be maintained in good conditions till the completion of the work.

The earthworks shall commence in accordance with the requirements specified in clause 10.0 of KOC Standard for Materials and Workmanship - " Site Preparation and Earthwork " ( KOC-C-005 1.

Weather Limitations

Concrete shall neither be mixed and placed when the ambient temperature is below 2 OC (35 OF) nor when the air temperature in the shade is 40 OC (1 04 OF) or above. No concrete shall be placed during high sand storms or rain unless adequately protected or unless otherwise directed by KOC. The temperature of the concrete when placed shall not exceed 32 OC.

Asphaltic concrete shall be installed when the atmospheric temperature in the shade is 1 0 OC (50 OF) or above. No work shall continue when the temperature is below 2 OC (35 OF) or when there is occurrence of continuous high winds, fog or rain other than very light sprinkle.

EARTH FOUNDATION WITH CONCRETE RING WALL

The Site for the tank foundation(s1 shall be prepared, cut and / or filled (as the case may be) and compacted I proof rolled with at least four (41 passes of a 10-ton vibratory roller to the design formation levels as indicated in the Contract specifications or approved construction drawings in conformity with dause 1 1.0 of KOC Standard KOC- C-005.

Any soil having susceptible characteristics encountered during the progress of the excavetion below the foundation or formation level shall be tested in accordance with dause 14.2 of KOC Standard KOC-C-005. If found to be unsuitable as base for tank foundations, it shall be excavated and removed from the Site to the KOC approved dump yard.

The extent of necessary excavation shall be agreed with KOC and the unsuitable material shall be replaced with suitably compacted approved fill material.

Excavation shall be carried out in accordance with the requirements of KOC Standard KOC-C-005. Manual excavations shall be made, as directed by KOC, in locations where required to protect the existing underground services.

Concrete Workg

Concrete shall be produced by weigh batching and mixed in mixer machine for pouring. The water cement ratio of the concrete mix shall be maintained for good workability and any adjustment needed shall be made for the aggregate moisture content at the time of mixing.

Concrete shall be evenly spread and compacted by a vibrator to produce a dense finish free from honeycombing, sags, bulges, thick or thin areas and any other visible defects.

All reinforcements shall be cut, bent, placed in the formwork and inspected by KOC before concreting in accordance with ACI 31 5 and ACI 31 8.

Curing

Curing for concrete shall be continued for at least 7 days by use of one of the following methods :-

a) Being kept damp by a continuous water spray.

b) Being covered with continuously wet burlap or fabric pads.

c) Being sprayed with water and immediately covered with a layer of waterproof paper meant for curing of concrete.

The concrete surfaces below the grade level shall be painted with three coats of modified bituminous paint, the total DFT being 1000 microns, then covered with 1000g polyethylene membranes.

Tolerances

The top of the concrete ring wall shall be level within + 3 mm (1 I8 in) between any two points of 9 m ( 30 ft) of the circumference and within + 6 mm (114 in) in the total circumference measured from the average elevation.

Backfilling & Compactio~

After the concrete ring wall being properly cured, inspected and approved by KOC, the backfilling shall commence around ring wall for the inside and outside areas of tank foundation.

t

Earth pad below the tank bottoms and outer areas of the ring wall shall be backfilled by spreading evenly successive layers of gatch not exceeding 200 mm loose depth. 'Each layer shall be rolled by rollers suitable for the type of soil and shall be thoroughly compacted to 95% of maximum dry density at optimum moisture content ( OMC ) as determined by ASTM D l 557, before depositing the next layer.

Prior to deposition, the fill material shall be wetted with water from KOC approved source within + 2 % of the optimum moisture content to achieve proper compaction as per above dause 12.3.2. However, before compacting, the natural

.. DOC. NO. KOC-C-026 I Page 26 of 38 I REV. 1 I

moisture content of the samples shall be verified at site by the Speedy Moisture Device or similar KOC approved instrument.

The compacted surfaces shall be field-tested to satisfy the requirements described in dause 14.0 of this Standard and shall meet all the requirements specified in KOC Standard KOC-C-005.

The layer of sand-gravel mix shall be evenly spread over the compacted gatch and shall be compacted to 95 % of maximum dry density.

The final layer of sand cushion below the tank bottom shall be spread when the tank fabrication commences and shall be adequately protected with covers so as to prevent any blowing-off of the sand partides by high winds or rain.

Membrane liner (if provided) shall be installed over the compacted gatch with minimum joints which shall be overlapped, bonded or welded to be leak tight. Liner seam shall be bonded to the concrete ring wall for leak tight connection. All perforations shall be sealed.

The installation of any embedded anodes, reference electrodes and associated cables below the earth pad for the specified cathodic protection system shall be carried out in accordance with KOC-L-026 and as per the KOC approved procedure. Care shall be taken that no damages to these materials shall occur during compaction of the fill materials.

As~haltic Concrete Application

General

The contractor shall submit the method statement detailing all the necessary equipment, tools and machines to be involved into the actual laying of lining by spraying or spreading for review and approval by KOC before any work commences.

Proportions & Mixing of Materials

The contractor shall submit for approval a proposed Job Mix Formula in line with the proportions of the materials specified in clause 10.0 of this Standard. The contractor shall also establish the optimum mixing temperature and shall test samples of materials to be used in accordance with dause 15.5.3 to ensure compliance with the requirements of this Standard prior to any applicstion of the material.

Surface Rwarstion

a) immediately before the application of surface protective layer over the compacted surfaces, all loose dirt, dust or other objectionable material shall be removed by means of power broom or Mower supplemented with hand brooms.

b) Any soft spots, me- en surfaces or irregularities in the surface shall be rectified by the contractor as directed by KOC to its full satisfaction prior to carrying out any hrrther work.

c) The asphaltic concrete shall be applied only on the dry s u r f a k of the' compacted outer surface of ring wall end if excessively dry, the surface shall be lightly

DOC. NO. KOC-C-026 I Page 27 of 38 I REV. 1

sprinkled with water just before the application to facilitate proper penetration or bonding of material.

Application Temperature

The mix temperature shall be within the limits set out in the approved Job Mix Formula when emptied from the mixer to a tolerance of f 10 % but in no case shall exceed 154 O C ( 31 0 O F 1. The minimum temperature of mix on delivery to job site shall not be less than 121 O C ( 250 O F ).

Application

a) When the compacted surfaces of the tank shoulder have been approved by KOC and weather conditions are suitable, 75 mm (3 in) thick protective layer of hot- mixed asphaltic concrete lining shall be immediately sprayed or spread over all the clean faces to prevent erosion of earth surfaces. The application shall meet the requirements of ASTM D3515.

b) Following the application of lining materials, the surface shall be allowed to dry without being disturbed for a minimum period of 48 hours or longer as may be necessary to attain proper bond after evaporation of the volatiles from the asphalt cement.

Protective Thickness

The thickness of surface protective layer shall be verified at site to a tolerance limits of + 5% over the minimum thickness of 75 mm.

EARTH FOUNDATION WITHOUT CONCRETE RING WALL

Construction of this type of tank foundation shall comply with all the material requirements as specified in clauses 10.1 to 10.5 except 10.4 ( in-situ concrete ) of this Standard.

Construction of this type of tank foundation shall follow the same procedures and requirements as specified in clauses 12.1 to 1 2.4 except 12.2 ( concrete works ) of this Standard.

The ring wall made of graded crushed stone or gravel (maximum 25mm size) with fine aggregates in accordance with clause 10.2 of this Standard shall be mixed with gatch as binder. Layers of 150mm depth shall be compacted with mechanical tampers to the designed slope as indicated in the approved construction drawing.

Water shall be added to the materials within f 4 % of the optimum moisture content to achieve proper compaction equivalent of 95% of maximum dry density.

Tolerances

The top of the stone ring wall shall be level within f 3 mm (118 in) between any two points of 9 m ( 30 ft) of the circumference and within -f 12 mm (1 12 in) in the total circumference measured from the average elevation.

DOC. NO. KOC-C-026 I Page 28 of 38 I REV. 1

REPAIR OF DEFECTS 1 DAMAGES

Subject to visual inspection of KOC, the contractor shall remove any soft patches, uneven surfaces or crevices by refilling and recompacting the demarcated areas of earthworks as directed till KOC is fully satisfied with the work.

In case the test results indicate that the field compaction does not satisfy the compaction equivalent in clause 12.3.2 of this Standard , the contractor shall carry out the necessary corrective measures as directed by KOC at his own expenses and without any cost to KOC whatsoever.

All refilling and rectification of materials involved in the rectification of defective works shall be executed in the manner so as to maintain compatibility complying with the requirements of clauses 10.1 & 12.3 of this Standard.

Concrete Work

The concrete work or part thereof shall be deemed to be defective I damaged, if the surface is found to bear the following :-

a) Large number of honeycombing I ~palling I bulging of concrete.

b) Large number of microcracks on surfaces due to extreme hot weather and lack of adequate curing.

C) Exposure of reinforcement and lack or loss of bond with concrete.

All repair and rectification work by the methods (patch work, re-concreting, epoxy based cementitious material or guniting 1 shall be carried out by the contractor as agreed by KOC.

Amhattic Concrete

Following application of the new asphaltic concrete over the shoulder of the tank, the protective layer having defects / damages shall be repaired completely by the contractor as directed by KOC. The Work or part thereof shall be deemed to be defective, if the surface over an area of 1000 cm20r more does not meet the tolerance limits specified in clause 12.4.7 of this Standard and / or is found to bear the following *-

a) Surface discontinuities such as pinholes, thin spots, voids, cracks, foreign inclusions or contamination in the protective surface over a large area.

b) Large number of Misters, wrinkles, floods, mgs, oversprays, lumps of material.

The protective layer within the defective / damaged areas shall be cut and removed in rectangular sections. The earth surfaces shall be deaned from any debris, lumps etc. and the disturbed areab) shall be prepared & compacted with the selected fill materials / gatch following the same procedure described in dause 12.3 of this Standard.

INSPECTION AND TESTING

General

KOC shall have the right to inspect all tools and equipment ; materials and workmanship involved in the construction of foundations for Storage Tanks to ensure compliance with this Standard.

The contractor shall submit for KOC approval a Quality Plan and a lnspection & Test Plan that will provide the detailed activities of the work in a chronological way. The Inspection and Test Plan shall have columns indicating the activity, the contractual and specification requirements, the method of verification, the acceptance criteria, the document ( test certificate or report ) that will be generated as well as columns for indicating KOC markings for witness (W), hold (HI, review (R), monitor (MI etc.

The contractor shall perform at all stages of Works all the inspections and appropriate tests that are necessary to assure that the materials and workmanship meet fully the requirements of this Standard.

Materials and Eaui~ment lnmection

All materials shall be inspected to ensure conformance with clause 10.0 of this Standard.

All equipment to be used in the earth filling & compaction and laying of in-situ concrete and asphaltic concrete shall be inspected to ensure compliance with the KOC Fire and Safety Regulations.

Visual Inspection

Compacted Earth Surfaces

After the earth surfaces being compacted and trimmed to the actual profile, a visual inspection shall be made by the contractor jointly with KOC to ensure that no soft patches, uneven surfaces or loose dust are left on the surfaces prior to commencing the application of sand-gravel mix or protective surface layer. Any rectification of defective work shall be carried out in accordance with clause 14.1 of this Standard.

Concrete Work

After removal of formwork, the concrete work shall be inspected by KOC to assure that the surfaces are free from any visible defects described in 14.2.1 of this Standard. All repair and rectification work shall be executed by the method statements which shall be approved by KOC.

Asphaltic Concrete

After application of asphaltic concrete materials and proper drying, it shall be inspected to assure that the final surfaces shall be free from any defects described in clause 14.3 of this Standard.

DOC. NO. KOC-C-026 I Page 30 of 38 I REV. 1

All the required tests shall be conducted on the materials by the contractor through an independent and reputed test laboratory, approved by KOC.

All the laboratory tests on the soil samples for selection of gat* i'suitable~fill~materials shall be carried out in accordance with clauses 14.2.2 through 14.2.4 of KOC Standard KOC-C-005.

All the laboratory tests on the materials specified in this Standard shall be conducted in accordance with the relevant BS & ASTM standards to satisfy the requirements of this Standard.

Field Tests

Earth Works

Field in-place density tests shall be performed in accordance with ASTM Dl 556 at not less than one test for every 500 m3 of compacted fill to satisfy the compaction equivalent in clause 12.3 of this Standard.

Smctural Concrete

a) Prior to commencing the concrete work for ring wall construction the contractor shall , prepare three ( 3 ) Nos. test cubes of 150 mm sizes in the standard moulds, conforming to the grade specified. The test cubes shall be made, cured, preserved, and tested in compliance with BS 1881 or ASTM C39 after 7 days to indicate a compressive strength of not less than 70 % of the compressive strength at 28 days.

b) Six (6) Nos. of representative test cubes of above sizes shall be made for every 20 m3 of concrete during the course of concrete pouring, cured, stored; and tested, three ( 3 1 after 7 & 28 days respectively to confirm the compressive strength specified in clause 10.4.7 of this Standard or as indicated in the approved construction drawing.

Asphattic Concrete

a) Sufficient number of samples shall be collected during the course of application from the appropriate sampling points as follows:-

t

i. From the tanker, in case of bulk delivery by road, immediately before discharge;

ii. From the storage tank immediately before mixing;

iii. From the tank or the spray bar of a bituminous distributor immediately before spraying.

b) Each sample shall be immediately subdivided into three ( 3 ) test samples, stored into dean and dry metal containers, labelled with time & date of sampling and sampling locations.

C) Testing of samples shall be carried out within 3 days after sampling and shall be conducted in accordance with the test methods of ASTM D2172.

QUALITY .ASSURANCE

The contractor / manufacturer shall operate a quality system preferably based on IS0 9000 series of Standards to satisfy the requirements of this Standard. Contractor / manufacturer shall demonstrate compliance by providing a copy of the accredited or the contractor 1 manufacturer quality manual. Verification of a contractor quality system is normally part of the pre-qualification procedure, and is therefore not detailed in the core text of this Standard.

DOCUMENTATION

General

All correspondence, instructions, drawings, data sheets, design calculations or any other information shall be in the English language. In the case of dual languages, one language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in SI units, unless otherwise specified.

All documents (texts, specifications, data sheets, methods, drawings etc.) shall be provided with electronic files in the approved softwares ( MsWord, Excel, Auto Cad etc. 1. Design calculations shall be submitted in the approved and widely used softwares, agreed by KOC.

Work Records and Reports

The contractor shall operate a detailed recording and reporting system on all aspects of works including inspections and testing. All relevant information shall be set out on a Site Record for Foundation Works within 48 hours of carrying out a specific work. A sample of this Site Record is shown in the Appendix - IV and shall be submitted in duplicate.

All test results of samples ( filling material, aggregates, cement, asphalt cement etc. ) hall be submitted to KOC for review and approval within 24 hours of completion of tests.

All field test results of samples (compacted fill, concrete cubes, asphalt concrete etc.) shall be reported to KOC for review and acceptance within 24 hours of completion of tests.

DOC. NO. KOC-CQ26 I Page 32 of 38 I REV. 1 1

APPENDIX- I : JYP, EARTH FOUNDATION OF TANK WITH CONCRETE RING WALL

TANK -

76m.m TEICK

GATCB MIHPACI%D g5X MAX. DRY DW LAYER COMPACTED

To 06% OF MAXIMUM ?OR lgAY DETECTION. PBOVDE DRY DENSllY 75mm DIAMETER PVC PIPES OR BQUAL AT NOT YORE TEAN SY B r m m CKNTRES AROUND PIIRIPHWY. M C MESH Mhnm

SCBEEN OVER msmE OPEN BND. BUNDING --/ CONCRETE

a. FANE PAD 10UNDATION SBAU COYPLY 'IFFH RBQvnzeYwn OF THlS KOC STANDARD & -ANT PlwBm BPICIFICILTION.

-6Am COMPACTED TO OSX MAX. DRY DlWSITY

APPENDIX - II : TYP. EARTH FOUNDATION OF TANK WITH CONCRETE RING WALL 1 WlTH EMBEDDED CATHODIC PROTECTION SYSTEM 2

75mm THICK- ASPHALTIC CONCRETE

CATCH COMPACTED 05% MAX. DRY DEN

(lmm TOTAL THICKNESS), COVERED m lOOOg

FOR LEAK DETECTION, PROVIDE--/ 75mm D W T E R PVC PIPES OR EQUAL AT NOT YORE THAN 6M B E T 5 N CENTRES AROUND PERIPHERY. PLASTIC YESH

L SOmm /

SCBEEN OVER INSIDE OPEN END BLXNDING CONCRETE

NOTES: 1. ALL DIKENQONS ARE IN YY. 2. REINFORCED CONCRETE SHALL COMPLY WITH

BBQuDUWNTS OF PROIgCT SPECIFICATION.

MK. DRY DENSITY TO FULL DEPTH OF BPJC W.

a. TANK PAD FOUNDATION SHALL COMPLY WITH REQTJIREYENTS OF THIS Itoc STANDARD & PROJECT ~ECIFICATION.

4. DEPITI: TO BE DECIDED BY TBE DESIGNER AS PER SR'B CONDITIONS BUT NOT LESS THAN 900m.m FOR D M 5 m AND 6OOmm FOR D<95m FROM PINISBED GRADE OR NATURAL GROUND LEVEL (NGL) WEICHEVEB I6 U l E R .

6. BgpgIl FIELEVANT DRAWINGS FOR CATHODIC PROTECTION OF TANK BOlTOYS. 7. IsJER (IF PROVIDED) TO Bg 3ONDED TO RINGWAIL ?'OR LEAK TIGHT CONNETION.

DOC. NO. KOC-C-026 I Page 34 of 38 I REV. 1

APPENDIX - Ill : N P . EARTH FOUNDATION OF TANK WITHOUT CONCRETE WALL RING

2Smm A S P U T IYPREGNATED BOARD

El

I- +'

OR 25mm WON-SHRINK GROUT

TANK - SHELL

7Smm THICK ASPHALTIC ~EiDmmiT, I---

1v- loZ ""*

3. DEPTH OF MUNDATION TO BE DBCIDQ) BY TEE Dmcm As PER SITE CONDXTIONS BUT NOT USS TUN OOOmm Ir6LOM FDUSHED OBaDB OR NATURAL GROUND lgVEL (NGL) VEICHgVlgR IS LOm

14.0 SlTE RECORD FOR FOUNDATION WORK

Prepared by ................................. Checked by ........................................ Date ................... Project No. .................................. Contract No. ..................................................................... .............................. Contractor Name ............................................................. Location KOC Drawing No. ................................ Type of Work : 00 New O Repair Type of Workmanship : 0 Site Preparation Earthwork D Concrete D Asphaltic Concrete Date of Commencement ................................ Time ........................... AM I PM Date of Completion ...................................... Time ........................... AM I PM - A. Site Preparation Details

A. 1 Commencement Requirements

Work 1 Excavation Permit obtained D Yes 0 No Give reasons ( i f No 1 .................................................................................... Approvals obtained Not Started Started D Completed Not Complted Give reasons ( i f Not 1 .....................................................................................

A.2 Drawings Site Information D Checked 0 Not Checked

A.3 Existing Services encountered 0 Yes 0 No Give details ( i f yes 1 ......................................................................................

A.4 Demolition required 0 Yes 0 No Give details ( i f yes ...................................................................................

A.5 Site Clearance D Not Started 0 Started 0 Completed 0 Not Completed

B. Weather Conditions

Maxm. Ambient Temperature .............. OC Relative Humidity ........................ % Minm. Ambient Temperature ............... OC Other Conditions : Cl Rainy 0 Windy

C. Earthwork Details

C.l Foundation Areas Generally in Cut fill 0 60th Borrow Pit required Yes No

C.2 Fill Materials

Excavated Materials if available 0 Suitable 0 Unsuitable 0 Mixed ( by visual inspection 1 Soil Samples tested from U Borrow Pit 0 Excavated Materials Suitable Materials 0 Approved D Not Approved ( by Lab. test results 1 Materials selected from O Borrow Pit D Excavation 0 Both Soil type approved as Fill .............................................................................

SITE RECORD FOR FOUNDATION WORK ( contd. )

C.3 Compaction

l'ype of Equipment used 0 Vibrating Rate 0 Mechmicd Rammer 0 Any Othe; (Specify)

Compaction by Fidd Trials D Approved D Not Approved

Compaction achieved 0 Yes 0 No

Give reasons ( if Not ) ................................................................................. D. Concrete Work Details

Grade of Concrete ................................. Temperature of Concrete .................... OC Mixing by weight : Cement ........................ Aggregates ..................... Admixture ............. Type of Equipment used : 0 Batching Piant O Truck-mounted Concrete Mixture 0 Any other

Details of Equipment : Capacity ................ Size ............................... Pressure .................... Any other ...................................................................................

Length Covered : .................................. m Time of Application : .............................. Hr.

............................. ........................... Curing Method Curing Period

Give reasons ( if extra period required 1 ......................................................................... E. protective Linina A~~ l i ca t i on

Asphaltic Concrete

Mixing Method ................................................ Mixing Time .................................. Application Temperature ...................... OC Viscosity ..................................

Application Rate ......................... kg per 8q.m

Details if any ( Specify ) ............................................................................................... .............................................................................................. Type of Equipment used

0.tdls of Equipment : Capacity .................... 6ite ....................... Qnuure ................ .......................... Area Covered : .................................. Sq.m Time of Application : Hr.

DOC. NO. KOC-C-026 I ---

REV. 1

SITE RECORD FOR FOUNDATION WORK ( contd. )

I

F. lns~ection 81 Testing

Inspection Frequency : 0 Daily 0 Weekly Any Observation ......................... Visual Inspection : Prepared Surface .............................. Concreted Surface ..................... ..............................

F.l Fill Materials for Foundations

Field In-Place Density Tests done : OYes O N o Field results : 0 Acceptable 0 Not Acceptable

................................................................... Corrective measures taken ( i f not acceptable 1

F.2 Concrete

Test Cube Sizes ......................... Concrete Temperature ................. OC

Compressive Strength : At age of 7 days ............... N I sq.mm At age of 28 days .............. N I sq.mm

Test results : 0 Acceptable 0 Not Acceptable

Corrective measures taken ( i f not acceptable ) ............................................................... F.3 Protective Lining

Asphaltic Concrete

Test Samples .................................. Mix Proportion .................................. Application Temp. ............ OC .......... OC Viscosity .................... ............... Lining Thickness .................. mm

Recorded By : A ~ ~ r o v e d By :

Name .............................................. Name ................................................... ............................................. Signature ......................................... Signature

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REMARKS :

DOC. NO. KOC-C-026 Page 38 of 38 I REV. 1 I

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC) consisting of the following :-

Mr. Ali H. Baba Mr. Mohd. Emam Mr. S. Kumar Dr. Mohammad llyas Mr. Khalid S. AI-AIi Mr. Henry S. Hill Mr. Jassem Al- Quraini Mr. S. Manickavachagam

( Standards Div. ) ( Insp. & Corr. Div. ( Standards Div. ( Standards Div. ) ( Maint. Proj. Div. ) ( Maint. Plng. Div. ) ( PMD - North ) ( Engg. Design Div. )

Chairman Deputy Chairman Secretary 1 Member Member Member Member Member Member

The draft of this Standard has been circulated to the KOC User Departments for their review and comments were received from the following :-

ENGINEERING GROUP

Gen. Supdt. Engg. Services Head of Team Engg. Projects ( N ) Gen. Supdt. Proj. Mgmt ( S&E

LOSS PREVENTION GROUP

Gen. Supdt. Consv. & Insp. Gen. supdt. Fire & Safety

MAINTENANCE GROUP

Gen. Supdt. Maint. Services Gen. Supdt. Maint. ( N&W ) Gen. Supdt. Maint. ( S&E )

INDUSTRIAL SERVICES GROUP

Gen. Supdt. Ahmadi Services

PRODUCTION & EXPORT OPERATIONS GROUP

Gen. Supdt. Marine & Export Opns Gen. Supdt. Prod. Services Gen. Supdt. Prod. Opns ( N&W ) Gen. Supdt. Prod. Opns ( S )

This KOC Standard for Storage Tank Foundation has been prepared by the Task Force ( TF-CIV.1 01 ) comprising of the following members :-

Mr. S. Kumar (Standards Div.) Team Leader I Author Tel. No. 61407 Mr. Javaid Masood (Engg. Design Div.) Member / Author (Part) Tel. No. 61322 Mr. Khalid Al- Sayed (Maint. Proj. Div.) Member Tel. No. 6161 3