CONCRETE DESIGN AND CONSTRUCTION

REVISED 12/93, 11/94

SEPTEMBER 1993 PAGE 1 OF 18

EGE 01-B-7 1993

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References General Design Materials 5.1 General 5.2 Concrete Mix 5.3 Reinforcement 5.4 Anchor Bolts 5.5 Grout Construction 6.1 General 6.2 Forms and Forming Details Reinforcement, Anchor Bolts, and Embedded Items 6.4 Joints 6.5 Concrete Mix 6.6 Concrete Placement 6.7 Finishes 6.8 Curing 7. Testing and Quality Control 8. Bibliography Appendix Additional Requirements for Concrete Exposed to Chloride History of Change 6.3

6.

1. SCOPE This Guide covers basic requirements for the use of concrete in the design and construction of general facilities. It does not cover all requirements for special types of concrete construction, such as offshore platforms. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. MRDC (Guide Sponsor) should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-B-3 EGE 01-B-8 EGE 01-B-9 EGS 1202 (1993) (1992) (1992) (1991) Structures and Equipment External Loading Design Basis Foundation Design Grout Foundation Systems

ACI (American Concrete Institute) Publications 117R 301 302R 305R (1990) (1989) (1989) (1991) Standard Tolerances for Concrete Construction and Materials Specifications for Structural Concrete for Buildings Guide for Concrete Floor and Slab Construction Hot Weather Concreting

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

306R 308 315 318 347 (1988) (1992) (1986) (1989) (1989)
PAGE 2 OF 18

REVISED 11/94
SEPTEMBER 1993

Cold Weather Concreting Standard Practice for Curing Concrete Details and Detailing of Concrete Reinforcement Building Code Requirements for Reinforced Concrete Guide to Formwork for Concrete

AASHTO (American Association of State Highway and Transportation Officials) Tests T260 (1990) Standard Method of Sampling and Testing for Total Chloride Ion in Concrete and Concrete Materials

ASTM (American Society for Testing and Materials) Standards A615 A706 C31 C39 C94 C150 C172 C618 (1992) (1992) (1991) (1986) (1992) (1992) (1990) (1992) Deformed and Plain Billet-Steel Bars for Concrete Reinforcement Low-Alloy Steel Deformed Bars for Concrete Reinforcement Making and Curing Concrete Test Specimens in the Field Compressive Strength of Cylindrical Concrete Specimens Ready-Mixed Concrete Portland Cement Sampling Freshly Mixed Concrete Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete

AWS (American Welding Society) Code D1.4 (1992) Structural Welding Code Reinforcing Steel

3. GENERAL 3.1 The design and construction of concrete shall be in accordance with project specifications and with the requirements of this Guide. Project specifications shall be prepared by the contractor and approved by Mobil. 3.2 All standards, codes, and specifications used in the preparation of a project specification shall be referenced therein along with sources from which copies are readily obtainable. 4. DESIGN 4.1 All design calculations, drawings, and specifications prepared by the contractor shall be checked and approved by an engineer authorized to perform such work by the governmental authorities having jurisdiction. Mobil approval of the engineer is required. 4.2 4.3 Copies of all design calculations, drawings, and specifications shall be submitted to Mobil for review. All concrete design shall conform to applicable requirements of ACI 318 unless noted otherwise herein.

4.4 Mixes for concrete shall take into account the special exposure requirements described in ACI 318, except as noted in this Guide. Where water penetration of concrete is a consideration in the design of a facility and must be minimized (for example, in cooling tower basins, pits below water level, and structures immersed in seawater), the concrete constituents, quality, and curing procedures shall be carefully specified to ensure both reduced permeability and control of cracking.

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 3 OF 18

REVISED 11/94
EGE 01-B-7 1993

4.5 4.6

Concrete exposed to chloride shall meet the requirements of the Appendix to this Guide. Minimum external loading shall conform to the requirements of EGE 00-B-3.

4.7 Concrete structural members constructed for ordinary plant installations shall be designed to have, at all sections, a calculated strength necessary to carry the following factored loads and forces:

General U=0.95D + 1.28W or 1.41E U=1.40D + 1.70 (L1) U=1.05D + 1.28 (L2) + 1.28W or 1.41E Vertical Vessel Support Design U=0.95 (EL) + 1.28W or 1.41 E U=1.05 (EL) + 1.28W or 1.41E U=1.40 (OL1) U=1.05 (OL1) + 1.28W or 1.41E U=1.15 (TL) U=1.05 (TL) + 0.32W Erection Loads U=1.05 (DS) + 1.05 (DE) + 0.64W U=0.95 (DS) + 0.95 (DE) + 0.64W

Horizontal Vessel Support Design U=1.05 (EL) + 1.28W or 1.41E or 1.28 (BP) U=1.40 (OL1) + 1.70 (TF) U=1.05 (OL1) + 1.28 (TF) + 1.28W U=1.05 (OL1) + 1.28W or 1.41E U=1.15 (TL) U=1.05 (TL) + 0.32W Pipe Supports and Pipeway Structures U=1.40 (OL2) + 1.70 (PTF) U=1.05 (OL2) + 1.28 (PTF) + 1.28W U=1.05 (OL2) + 1.41E U=0.95 (OL2) + 1.28W or 1.41E U=1.15 (TL) U=1.05 (TL) + 0.32W

Symbols
U = Required strength to resist factored loads or related internal moments and forces. (BP) = Tube bundle pushing and pulling forces along the longitudinal axis of the vessel. D = Dead loads including weight of structure and all materials of construction to be permanently supported by the structure. (DE) = Deadweight of equipment without loose internals, piping, or insulation. (DS) = Deadweight of structure without fireproofing. E = Earthquake load. (EL) = Empty load including weight of structure, platforms, equipment (including internals), attached piping, fireproofing, and insulation. (L1) = Live loads including snow and ice loads, impact, surge forces, vibration, thermal forces, and longitudinal and lateral horizontal forces from moving equipment. (L2) = Live loads excluding snow and ice loads, impact, surge forces, vibration, thermal forces, and longitudinal and lateral horizontal forces from moving equipment. (OL1) = Operating load including the weight of any liquids or solids within the vessel, attached equipment, and piping during normal operation, in addition to all other loads used in the empty condition. (OL2) = Operating load including the weight of any liquids or solids within piping and equipment during normal operation, in addition to the weight of piping, equipment (including internals), structure, platforms, fireproofing, and insulation. (PTF) = Longitudinal pipe thermal force, including pipe anchor (if any). For horizontal thermal sliding force, use 10 percent of the vertical operating pipe load being supported. Exception: When three or fewer pipes are being supported, use 40 percent of the vertical operating pipe load of the heaviest pipe. (TF) = Thermal friction forces. (TL) = Test load including all loads used in the empty condition, as well as the weight of test water in all equipment and piping loaded simultaneously. W = Wind load.

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

PAGE 4 OF 18

REVISED 11/94
SEPTEMBER 1993

4.8 All concrete, except that used for fill material, encasement of steel electrical duct, and buried piping thrust blocks, shall be reinforced with at least nominal reinforcement, spaced at a maximum of 250 mm (10 in.) in both directions, on all faces to eliminate cracking. Thrust blocks and pipe anchors shall be provided with reinforcement if required by the magnitude of the load. 4.8 Design of machinery foundations shall take fatigue stresses into account.

4.9 Project specifications shall define the maximum acceptable settlement that will be used in the sizing of foundations. 4.10 All structural steel, including equipment and skids, shall be supported abovegrade on pedestals. As a minimum, all indoor and outdoor pedestals shall be 150 mm (6 in.) above adjacent grade. When the surface of the adjacent grade is earth or stone, this minimum should be increased to keep structural steel free from the accumulation of dirt. 5. MATERIALS 5.1 General

Stored materials for concrete construction, including but not limited to cement, aggregate, and reinforcement, shall be protected from deterioration and intrusion or encrustation of foreign matter. Any material that has deteriorated, has been damaged, or is contaminated by deleterious matter shall not be used in construction. 5.2 Concrete Mix

5.2.1 All cement used in construction shall conform to ASTM C150. Cement for general construction shall be standard Portland cement, Type I or II. Type V cement shall be used for the construction of any vessel, pit, tank, etc., that contains sulfur or any chemical mixture containing sulfur. Cement used for construction of concrete subject to exposure to sulfate in soil or groundwater shall be either Type V or Type II with the addition of Class F pozzolan fly ash to the concrete mix in conformance with ASTM C618. Type III cement shall only be used following a determination that heat of hydration will not be detrimental to the final concrete product. 5.2.2 Coarse aggregate for normal-weight concrete shall be one of the following materials, in order of preference: (1) crushed stone, (2) crushed gravel, and (3) gravel. 5.2.3 Water used in concrete and grout shall be potable. It shall not contain any chemicals deleterious to the concrete. 5.2.4 Notwithstanding the provisions of the Appendix to this Guide, the addition of admixtures to concrete, except for the air-entraining agent and coloring for electrical conduit encasement, will be permitted only with Mobil approval. 5.2.5 Concrete for encasement of underground electrical conduit shall be colored by using one percent of red oxide by weight of cementitious material.

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 5 OF 18

REVISED 11/94
EGE 01-B-7 1993

5.3 5.3.1

Reinforcement All reinforcement shall be new material.

5.3.2 Reinforcing bars shall conform to the requirements of ASTM A615, Grade 60 unless noted otherwise herein. However, bars that are 10 mm (3/8 in.) or less in diameter and that are used as ties may conform to the requirements of ASTM A615, Grade 40. The splicing of reinforcement by welding shall be permitted only with prior approval of Mobil and in accordance with AWS D1.4. Bars that are to be spliced by welding and that conform to the requirements of ASTM A615, Grade 60 shall have: (a) (b) (c) A maximum carbon content of 0.3 percent A maximum sulfur content of 0.06 percent A maximum phosphorus content of 0.06 percent.

Otherwise, they shall conform to the requirements of ASTM A706, Grade 60. 5.3.3 Reinforcement shall be detailed, bent, and placed in accordance with ACI 315 and ACI 318. All reinforcement shall be bent cold. Reinforcing steel shall not be bent or straightened in a manner that will injure the material. When bars have bends that are not specified on the drawings or when bars have kinks, they shall not be used. 5.4 Anchor Bolts

For anchor bolt requirements, refer to EGE 01-B-8. 5.5 Grout

For grout requirements, refer to EGE 01-B-9. 6. CONSTRUCTION 6.1 General

6.1.1 All concrete construction shall conform to the requirements of ACI 301 and ACI 302 as applicable unless noted otherwise herein. Project specifications shall refer to these and other applicable documents listed under Bibliography (Section 8 of this Guide). 6.1.2 Construction shall be monolithic as much as possible. The location of all joints shall be shown on the drawings. Additional joints shall only be provided with prior approval of Mobil. Where liquidtight construction is required, suitable Mobil-approved water stops and joint sealers shall be provided in all joints. 6.1.3 Where liquidtight construction is to contain a liquid, it is recommended that the completed construction be hydrostatically tested before being placed in service. 6.2 6.2.1 Forms and Forming Details All concrete shall be placed in forms. Casting of concrete against soil shall not be permitted.

6.2.2 For concrete surfaces that will be above final grade or that will be less than 300 mm (12 in.) below final grade, the inside surfaces of the forms shall be one of the following:

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993 (a) (b) Metal Plywood
PAGE 6 OF 18

REVISED 11/94
SEPTEMBER 1993

(c) Other material that gives an equally smooth concrete surface free from wrinkles, cracks, fin projections, or other irregularities. Forms for a concrete surface that will be buried a minimum of 300 mm (12 in.) below final grade may be constructed of dressed lumber. 6.2.3 Tolerances for formwork shall be within the limits specified in ACI 117, ACI 301, and ACI 347.

6.2.4 The use of coatings for forms and/or the use of release agents shall conform to the requirements of ACI 301 and ACI 347. 6.2.5 The inside surfaces of wood forms shall be soaked with clean water within one-half hour before concrete is poured. Forms and adjacent concrete surfaces shall be saturated, but ponding on any surfaces is not permitted. 6.2.6 Forms and shoring for slabs, beams, and joists shall not be removed prior to the concrete reaching a minimum of 70 percent of its specified compressive strength. Sufficient strength shall be demonstrated by submitting for approval a structural analysis and suitable tests on materials, using field-cured cylinders. The specified compressive strength of the concrete shall be based on 28-day test cylinder breaks. Exception: When Type III cement is used, the compressive strength shall be based on seven-day test cylinder breaks. 6.3 Reinforcement, Anchor Bolts, and Embedded Items

6.3.1 When splices of reinforcement are not shown on drawings, the splices shall be approved by Mobil. Splices shall conform to the requirements of ACI 318, except that lap splices shall have a length of not less than 30 times the nominal diameter of the bars. 6.3.2 Anchor bolts and other items to be embedded in concrete (such as inserts, hangers, pipe supports, pipe sleeves, conduit, and drains) shall be placed and secured in position before any concrete is placed. The securing of these items in position by welding or tieing to reinforcing bars shall not be permitted. These items must be isolated from the reinforcement by at least 13 mm (1/2 in.) of concrete. Anchor bolts shall be set by using templates placed at the approximate elevation of baseplate or equipment bases or frames. Anchor bolts shall be carefully plumbed and checked for location and elevation. They shall be held in position rigidly to prevent displacement while concrete is being placed. 6.3.3 Threads on anchor bolts shall be protected at all times against damage and corrosion. Minimum protection shall be provided by greasing and wrapping of the threads. 6.4 Joints

6.4.1 Reinforcing steel and mesh shall be continued across all joints except expansion joints. All expansion joints shall be provided with smooth dowels with sleeves on one end to permit sliding where it is required to transfer loading from one side of the joint to the other or to maintain surface alignment (for example, slabs on grade). Expansion joints shall be constructed with a preformed expansion joint filler material or other approved device to allow for expansion. Joint sealer shall be provided to ensure that foreign substances are prevented from entering the joint.

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 7 OF 18

REVISED 11/94
EGE 01-B-7 1993

6.4.2 Expansion joints for slabs on grade, wall construction, and other appropriate structures shall be provided at a maximum spacing of 24.4 m (80 ft). These joints shall be constructed so that they pass completely through the concrete section. 6.4.3 Contraction and/or construction joints for slabs on grade, wall construction, and other appropriate structures shall be provided at a maximum spacing of 6.1 m (20 ft). These joints shall be formed by scoring of the concrete prior to taking its initial set or by saw cutting within 24 hours after placing. The depth of the joints shall extend a minimum of one-third the thickness of the concrete section. 6.5 Concrete Mix

6.5.1 All concrete shall be "Central Mix" in accordance with ASTM C94, except when it is impossible to furnish this type of mix to the project site. 6.5.2 Mix proportions shall be determined by using methods based on "Field Experience and/or Trial Mixtures," as described in ACI 318. The proportioning of the mix using only the "Water/Cement Ratio" method described in ACI 318 shall not be permitted. 6.5.3 Acceptability of the selected mix proportions shall be established in accordance with ACI 318. The contractor shall submit the following data to Mobil for review within 30 days before the initial pour: (a) (b) (c) Weight of each material to be used for one cubic meter or one cubic yard of concrete Certification that all materials conform to specified requirements Slump range

(d) Documentation, as required by ACI 318, attesting that the proposed proportions will produce a 28-day compressive strength equal to or greater than the specified compressive strength. 6.6 Concrete Placement

6.6.1 The surface of hardened concrete against which fresh concrete is to be placed shall first be roughened by an approved method, such as sandblasting or chipping. This procedure shall expose the aggregate and remove all laitance, loose or damaged particles, and any deleterious matter that could prevent a bond between existing and new concrete. The surface of the hardened concrete shall then be thoroughly cleaned to remove all debris and dust. 6.6.2 Surfaces of previously hardened concrete that are not treated with bonding adhesive (against which fresh concrete is to be placed) shall be moistened with clean water prior to the placing of fresh concrete. Surfaces shall be saturated but free from ponding when the concrete is placed. 6.6.3 Placing of concrete in water shall not be permitted without prior approval from Mobil.

6.6.4 Concrete shall not be placed without prior approval from Mobil when the air temperature during the pour or within 72 hours thereafter is expected to fall below 4C (40F). 6.6.5 Concrete placed and/or cured in cold weather [air temperature 4C (40F) or below during any part of the day] shall be mixed, placed, and protected in accordance with ACI 306, except that the minimum time for protection of the concrete shall be seven days. The addition of salt, ethylene glycol, calcium chloride, or other chemicals to a concrete mix to prevent freezing shall not be permitted.

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

PAGE 8 OF 18

REVISED 11/94
SEPTEMBER 1993

6.6.6 The degree to which hot weather affects the placing and curing of concrete depends mainly on a combination of temperature and humidity. Combined climatic factors of an air temperature of 24C (75F) and a relative humidity below 30 percent are sufficient to be potentially critical for proper placing of concrete, while an air temperature of 38C (100F) and a relative humidity above 80 percent may not be as critical. When temperatures at the site of concrete placement are expected to exceed 21C (70F), ACI 305 should be reviewed and all concrete construction procedures shall comply with the requirements therein. 6.6.7 No concrete shall be placed before all adjacent operations that might be detrimental to the proper setting and curing of concrete, such as pile driving, have been completed. 6.6.8 Concrete shall be placed so as to avoid segregation of the materials. In placing the concrete, chutes or troughs shall be used to prevent a free fall in excess of 1.2 m (4 ft). 6.6.9 Once placement of concrete has started, it shall be carried on as a continuous operation until the placing of the block, panel, foundation, etc., is complete. A pour shall not be considered continuous if a surface is allowed to stand more than 15 minutes before additional concrete is poured against it and made integral with it. Construction joints shall not be permitted except when shown on drawings or approved by Mobil. 6.6.10 The type of vibrating equipment and number of vibrators used on each pour shall be approved by Mobil prior to the placing of an order for concrete. 6.7 Finishes

6.7.1 In general, the various types of finishes and finishing tolerances are described in ACI 301. Project specifications shall define the acceptable finishes for the various structures and concrete items on the construction site. The finishes described in the chapter titled "Slabs" in ACI 301 may be used for abovegrade top surfaces of equipment and structural steel supports. In addition, the following shall be done: (a) Roadway surfaces shall receive a wood float treatment and then a broom finish by drawing a wire broom perpendicular to the direction of normal vehicle traffic. Minimum depth of grooves or corrugation shall be 3 mm (1/8 in.) (b) Outdoor surfaces subject to pedestrian traffic only shall be roughened by means of a wood float to provide a nonslip, smooth, even-textured surface. (c) Tops of all abovegrade equipment and tops of structural steel foundations shall be roughened by means of a wood float to provide a smooth, even-textured surface. 6.7.2 Prior to application of the final surface finish, the concrete shall be steel troweled to produce a dense surface. 6.7.3 6.7.4 6.8 At no time during the finishing operation shall dry cement be used to absorb excess water. For procedures for the repair of surface defects after removal of forms, see ACI 301. Curing

6.8.1 It is essential to emphasize and specify in detail the need, as well as the methods to be used, to minimize moisture losses from newly placed concrete. Inadequate curing is one of the primary causes of cracking and surface deterioration of the final concrete product.

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 9 OF 18

REVISED 11/94
EGE 01-B-7 1993

6.8.2 Acceptable measures to prevent the loss of moisture during the curing period are described in ACI 318 and fully detailed in ACI 308. It is recommended that "moist curing" be used when possible, with particular emphasis on ponding or continuous sprinkling. This type of curing not only provides a cooling effect for temperature control but also provides a very visible means of monitoring the curing operations. 6.8.3 The use of liquid membrane curing compounds shall be approved by Mobil.

7. TESTING AND QUALITY CONTROL 7.1 Project specifications shall indicate the minimum testing requirements for materials used in concrete and for fresh concrete, the specific tests to be performed, and the frequency of the tests. Type and frequency of testing will depend mainly on the sophistication of the concrete suppliers in the vicinity of the construction site and on their plant facilities, in-house testing procedures, and testing facilities. In addition to the required tests on materials to ensure that they comply with the specifications, the following onsite testing shall be performed (in accordance with the appropriate ASTM standard) to ensure concrete quality: slump, density, and entrained air content. 7.2 All testing of materials for concrete and concrete samples shall be performed by a qualified testing consultant or a company approved by Mobil. 7.3 Strength testing of placed concrete shall be in accordance with the requirements of ACI 301 and ACI 318, except as noted herein. 7.4 Samples of concrete for compression tests shall be taken on each day that the concrete is placed. The concrete shall be sampled, cured, and tested for compressive strength in accordance with ASTM C172, C31, and C39. There shall be a minimum of four test cylinders per sample. For large continuous pours, no less than one sample shall be taken for each 38 m (50 yd) of concrete placed, or for each portion thereof. In the case of small pours, there shall be a minimum of one sample. 7.5 Three test cylinders shall be cured under standard moisture and temperature conditions in accordance with ASTM C31. The fourth test cylinder shall be cured in the field under similar conditions for a minimum of 28 days, unless directed otherwise by Mobil. 7.6 One of the moisture-cured samples shall be tested seven days after the concrete is poured; the other two shall be tested 28 days after the concrete is poured. The field-cured sample shall be marked, stored, and tested when directed by Mobil. 7.7 Project specifications shall indicate the quantity and distribution of the reports on tests prepared and performed by a Mobil-approved testing laboratory. Data to be included in the test report on the compressive strength of the concrete shall include, but not be limited, to the following: Identification of the structure where concrete was placed Design strength Quantity of concrete placed Proportions of concrete mix Water/cement ratio Maximum size of coarse aggregate

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993 Slump measurement Time of day and air temperature when samples were taken Date poured Required and actual age of specimen at time of test Name of inspector. 8. BIBLIOGRAPHY
PAGE 10 OF 18

REVISED 11/94
SEPTEMBER 1993

The following publications are not specifically referred to herein; however, they are applicable to concrete design and construction.
Mobil Engineering Guides EGE 01-B-2 EGE 31-B-1 EGS 1210 (1988) (1989) (1993) Surfacing, Paving, and Roadways Steel Structures Design and Fabrication Tank Foundation Systems

ACI (American Concrete Institute) Standards 211.1 211.2 214 304R (1991) (1991) (1977) (1989) Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete Standard Practice for Selecting Proportions for Structural Lightweight Concrete Recommended Practice for Evaluation of Strength Test Results of Concrete Guide for Measuring, Mixing, Transporting, and Placing Concrete

ASTM (American Society for Testing and Materials) Standards A185 Rev A A193 A307 Rev A C33 C138 C143 Rev A C260 C309 C494 (1990) (1992) (1992) (1992) (1981) (1990) (1986) (1991) (1992) Steel Welded Wire Fabric, Plain, for Concrete Reinforcement Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength Concrete Aggregates Unit Weight, Yield, and Air Content (Gravimetric) of Concrete Slump of Hydraulic Cement Concrete Air-Entraining Admixtures for Concrete Liquid Membrane-Forming Compounds for Curing Concrete Chemical Admixtures for Concrete

ICBO (International Conference of Building Officials) Code (1991) Uniform Building Code PCI (Prestressed Concrete Institute) [Refer to applicable publications.]

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 11 OF 18

REVISED 11/94
EGE 01-B-7 1993

APPENDIX ADDITIONAL REQUIREMENTS FOR CONCRETE EXPOSED TO CHLORIDE

A-1.

SCOPE

This addendum covers additional requirements for design and construction of concrete exposed to chloride. A-2. APPLICABILITY

The requirements of this Appendix apply to all Mobil facilities in locations where corrosive soils are known to exist or as determined by laboratory soil testing. A-3. For such applications, the following requirements shall apply.

A-3.1 When exposed to chloride, durable concrete capable of resisting chloride attack and maintaining its original quality and serviceability shall be used. Such concrete shall have low permeability, high density, high strength, and the ability to obstruct chloride penetration into the concrete by diffusion, absorption, or hydraulic pressure. As a minimum the concrete shall meet the following requirements: (a) (b) Maximum water/cement ratio shall be 0.40. Cement content shall not be less than 400 kg/m (675 lb/yd ).
3 3

(c) In hardened concrete at ages from 28 to 42 days, the maximum chloride ion concentration contributed from all ingredients including water, aggregates, cementitious materials, and admixtures shall not exceed either of 0.10 percent water soluble, as tested per AASHTO T-260 or 0.15 percent acid soluble as tested per ASTM C1152, by weight of cement. (d) For fresh concrete, the total water soluble sulfate content from all sources, expressed as SO3, shall not exceed 4.0 percent by weight of cement. (e) Minimum concrete compressive strength at age 28 days shall be 41.1 MPa (6000 psi). Design and proportioning of concrete members, however, shall be based on 27.6 MPa (4000 psi) to ensure well-balanced designs. A-3.2 A high-range water-reducing (superplasticizer) admixture shall be used to improve workability and impermeability. Other water-reducing and setting-retarding admixtures may be used in combination with the superplasticizer to decrease the rate of concrete hardening, subject to Mobil approval. A-3.3 The use of silica fume in concrete mix shall be subject to Mobil approval.

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

PAGE 12 OF 18

REVISED 11/94
SEPTEMBER 1993

A-3.4 Silica fume has a direct effect in reducing the concrete permeability and absorption and in increasing its sulfate resistance. However, because silica fume requires more mixing water and reduces workability, superplasticizer must always be used with silica fume. The amount of silica fume in the concrete mix shall not exceed 10 percent by weight of the required cement. A-3.5 Silica fume makes highly cohesive concrete with almost no segregation or bleeding. With little or no bleed water at the concrete surface for evaporation, plastic cracking can quickly develop on windy and hot days. Proper precautions, such as shielding from wind and direct sun, must be taken. A-3.6 All foundations shall be installed on a layer of structural plain concrete that is 75 mm to 100 mm (3 in. to 4 in.) thick and on a liner in the form of polyethylene sheet that is a minimum thickness of 0.25 mm (10 mils). The liner shall be installed between the foundation bottom and the top of plain concrete. The plain concrete layer shall extend a minimum of 100 mm (4 in.) beyond all foundation edges. Liner overlap shall be a minimum of 300 mm (1 ft). The liner shall extend a minimum of 150 mm (6 in.) beyond all foundation edges. A-3.7 The minimum concrete cover for all reinforcement in concrete in contact with soil shall be 75 mm (3 in.). A-3.8 All concrete shall be moist cured. Curing shall commence immediately after finishing and continue for a minimum of 14 days. A curing period of 28 days is preferred for surfaces which are to receive a waterproofing barrier (see Paragraph A-3.9). A-3.9 An impermeable waterproofing barrier shall be applied on all foundation surfaces, except foundation bottoms, from 300 mm (1 ft) above finished grade to the founding level. The waterproofing barrier shall be in the form of 100 percent solid liquid membrane applied in accordance with the manufacturers recommendations. Membrane sheeting may be used, subject to prior Mobil approval. Where the possibility of airborne chloride exists, such as in marine environment, the waterproofing barrier shall extend to include all aboveground concrete members exposed to weather conditions. A-3.10 Epoxy-coated reinforcement rebars shall not be used without prior Mobil approval. A-3.11 The following checklist contains critical requirements that must be addressed in detail in the project specification:

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 13 OF 18

REVISED 11/94
EGE 01-B-7 1993

CONCRETE IN CHLORIDE ENVIRONMENT REQUIREMENTS CHECKLIST

1. QUALITY REQUIREMENTS CONCRETE MIXING AND PLACEMENT Subject Specification Remarks Cement content for structural plain concrete may vary depending on size and criticality of concrete element and on ambient condition. Determine sulfate content by soil investigation. Follow Table 4.2.1 of ACI 318-89 to determine exposure level. Pozzolan can be in the form silica fume. Concrete containing silica fume is susceptible to shrinkage cracks due to silica fumes high water demand. High level of workmanship and test placements are required. Silica fume is not essential for producing concrete meeting the requirements of this checklist. Specified W/C ratio is based on saturated surface dry (SSD) aggregates, ASTM C-127 and ASTM C-128.

Cement Content:
Reinforced concrete Structural plain concrete 400 kg/m 3, minimum 350 kg/m 3, minimum Sulfate Exposure: Negligible Moderate Severe Very Severe Cement Type: ASTM C-150 I II V V + Pozzolan

Cement Type:
Determined based on sulfate concentration in soil and ground water.

Pozzolanic Materials:
C C C

Silica fume Fly ash Blast furnace slag

Not withstanding the above minimum cement requirement and subject to Mobil approval, silica fume may be utilized in the concrete mix by up to 10% of the cement weight.

Maximum Water/Cement (W/C) Ratio:

Reinforced concrete Structural plain concrete 0.40 0.45

Admixtures:
Superplasticizer Optimum dose shall be determined by production equipment trial mixes. Subject to Mobil approval . Other admixtures No other admixtures are allowed. Superplasticizer is mandatory to enable mixing with low W/C ratio (0.40). When water reducer is used, the total dose of superplasticizer plus water reducer shall be determined by production equipment trial mixes.

Water-reducing retardant

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

PAGE 14 OF 18

REVISED 11/94
SEPTEMBER 1993

CONCRETE MIXING AND PLACEMENT Contd Subject Specification Sulfate Chloride Remarks Additionally, total chloride content in hardened concrete shall not exceed 0.10% water soluble (AASHTO T260) or 0.15% acid soluble (ASTM C1152) by weight of cement.

Maximum Limits of Chloride and Sulfate Contents in Ingredients:

Water 100 PPM 500 PPM (ASTM (ASTM D-516) D-512) Sand 0.05%* 0.01%* (BS-812) (BS-812)

*By weight, water soluble

Water pH: Curing:

Uncoated surfaces Surfaces to be coated

5.5 to 8.5 Curing compound shall not be used on surfaces to be coated. Longer curing time is preferred for surfaces to be coated (sealed), up to 28 days.

14 days moist Curing 14 days moist Curing

MIX PERFORMANCE FRESH CONCRETE

Subject

Specification 25C (77F) maximum at time of placement (ASTM C-1064).

Remarks Due to high cement content, chilled mixing water to 4C (39F) or less and/or ice will normally be needed to meet this requirement. Other measures such as storing the aggregates in shade are also required in hot weather conditions.

Temperature:

Workability:

Slump shall be such that concrete can be transported, placed, and consolidated without segregation (ASTM C-143). 2.0%, maximum. ASTM C-231

With the mandatory use of superplasticizer, no slump requirement should be set as long as concrete is not segregated. Not applicable to concrete subject to freezing and thawing when air-entraining admixture is utilized.

Air Content

Unit Weight:

2400 kg/m 3, minimum. ASTM C-138

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 15 OF 18

REVISED 11/94
EGE 01-B-7 1993

MIX PERFORMANCE HARDENED CONCRETE Subject Specification Remarks

Strength:
7 days 28 days 6000 PSI (ASTM C-39) (420 kg/cm 2) 4000 PSI (ASTM C-39) (280 kg/cm 2) Design should be based on 4000 PSI (280 kg/cm 2) strength.

Maximum Chloride Content:

Either 0.10% water soluble per AASHTO T-260 or 0.15% acid soluble per ASTM C1152, by weight of cement. Maximum of 4.0% by weight of cement, water soluble (BS-1881). At age 28 - 42 days, shall fall in the "VERY LOW" range when tested per ASTM C1202. and The amount of chloride penetrating the concrete when tested for long-term chloride penetration per AASHTO 259, shall not exceed 0.02% by weight of cement. BS-1881

Sulfate Content:

Chloride Permeability:

Results from AASHTO T-259 are more reliable; however, the test needs 125 days to complete. Therefore, early planning is crucial. Subject to Mobil approval, suppliers records of previous testing for AASHTO T-259 may be accepted after being verified by ASTM C1202.

Water Absorption: Volume of Permeable Voids:

3.0% maximum (ASTM C-642) 7.0% Maximum (ASTM C-642)

At age 28 to 42 days At age 28 to 42 days

TESTING REQUIREMENTS Ingredients

C C C C

Fresh Concrete
C C C C

Hardened Concrete
C C C C C C C

Water Sand Coarse Aggregates Cement

Temperature Slump, for workability and no segregation Air Content Unit Weight

Strength Chloride Content Sulfate Content Specific Gravity Water Absorption Volume of Permeable Voids Chloride Permeability

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

2. PROTECTION REQUIREMENTS Method Requirement Maximum use for secondary foundations and underground facilities.
PAGE 16 OF 18

REVISED 11/94
SEPTEMBER 1993

Remarks For small foundations (when feasible), manholes, catch basins, duct banks, fence foundation, .. etc. Use same concrete mix as foundation mix to avoid possible confusion. Sheet overlapping shall be a minimum of 300 mm (1 ft). Excessive cover may lead to shrinkage cracks due to high cement content. Apply per manufacturers instructions. Two coats over a primer are usually recommended.

Structural Plain Concrete:

Mud Mat:

75 to 100 mm thick, under all foundations. Minimum 10 mil (0.25 mm) thick, between foundation bottom and top of mud mat. 75 mm (3 in.) minimum . 100 mm (4 in.) maximum. Impermeable waterproofing in the form of 100% solid liquid membrane on all surfaces in contact with soil to 300 mm (1 ft) abovegrade. When airborne chloride exists, aboveground exterior concrete surfaces shall be coated. Needs prior MTC approval. Limited applications. Needs prior MTC approval.

Polyethylene Sheet:

Concrete Reinforcement Cover: Surface Coating:

Epoxy Coated Rebars: Cathodic Protection:

Not recommended for new concrete, as more positive protection systems (coating and sheeting) will have to be dropped in order for the CP to work.

MOBIL ENGINEERING GUIDE

SEPTEMBER 1993 PAGE 17 OF 18

REVISED 11/94
EGE 01-B-7 1993

3. REPAIR METHODS Method Description Clean and restore damaged surfaces and reinforcement. Add redundant structural system. Modify foundation configuration to eliminate the need for original reinforcement. Viable if deterioration still in early stages. Remarks Used on minor foundations, has limited repair life. Very long repair life. Recommended for major equipment foundations.

Conventional:

Structural:

Cathodic Protection:

Needs maintenance and monitoring.

Abbreviations: AASHTO: ACI: ASTM: BS: American Association of State Highway and Transportation Officials American Concrete Institute American Society for Testing and Materials British Standards

MOBIL ENGINEERING GUIDE EGE 01-B-7 1993

PAGE 18 OF 18

REVISED 11/94
SEPTEMBER 1993

HISTORY OF CHANGE

The history of change contained herein does not constitute a complete listing of revisions and changes made to this document. Only revisions and changes of significant technical content (per sponsor and Steering Committee) are listed. EGE 01-B-7 1993, Rev. 11/94
The Appendix has been expanded to include a Concrete in Chloride Environment Requirements Checklist.