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SPECIFICATION

Project: EPF-CPF construction

CIVIL & EARTH WORKS SPECIFICATION

00 14/11/2016 For review WKR RTR KGR

Re Date Description Prepared by Checked by Approved by Company Approval

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SPECIFICATION

Project: EPF-CPF construction

SUMMARY

A - INTRODUCTION ....................................................................................................................................... 6

1. Project Description ................................................................................................................................. 6

2. General ...................................................................................................................................................... 7
2. 1. Scope ........................................................................................................................................................... 7
2. 2. Environmental Data ................................................................................................................................. 7
2. 3. Codes, Standards and Regulations ..................................................................................................... 7
2. 4. Civil & Structural Standards................................................................................................................. 7
2. 5. Priority of Documents ............................................................................................................................ 9

B - EARTHWORKS SPECIFICATION ....................................................................................................... 10

1. Introduction ........................................................................................................................................... 10

2. Site Preparation ..................................................................................................................................... 10


2. 1. Staking Out .............................................................................................................................................. 10
2. 1. 1. General Staking Out ............................................................................................................... 10
2. 1. 2. Boundaries For Underground Networks ........................................................................... 10
2. 2. Site Clearance ......................................................................................................................................... 10
2. 3. Area Preparation For Earthworks ...................................................................................................... 11
2. 3. 1. Scraping ..................................................................................................................................... 11
2. 3. 2. Compaction Of Soil Under The Fill ..................................................................................... 11
2. 4. Earth Moving ........................................................................................................................................... 11
2. 5. Pits, Quarries And Material Deposits ............................................................................................... 12
2. 5. 1. Investigation For Borrow Areas ........................................................................................... 12
2. 5. 2. Provisional Deposits ............................................................................................................... 12
2. 5. 3. Permanent Deposits ............................................................................................................... 12

3. Excavation Works .................................................................................................................................. 13


3. 1. General ...................................................................................................................................................... 13
3. 2. Definition Of Excavation Types ......................................................................................................... 13
3. 2. 1. Top Soil Removal ..................................................................................................................... 13
3. 2. 2. General Excavation ................................................................................................................. 13
3. 2. 3. Limited Section Excavation: Trench excavation ............................................................. 13
3. 3. Definitions Of Excavation According To The Soil Nature .......................................................... 13
3. 3. 1. Earth Excavation ...................................................................................................................... 13
3. 3. 2. Soft Rock Excavation .............................................................................................................. 14

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SPECIFICATION

Project: EPF-CPF construction

3. 4. General Instructions.............................................................................................................................. 14
3. 5. Methods Of Excavation ........................................................................................................................ 14
3. 5. 1. Requirements ........................................................................................................................... 14
3. 5. 2. Tolerances ................................................................................................................................. 14
3. 5. 3. Use Of Excavation Materials ................................................................................................ 14

4. Drainage and Dewatering ................................................................................................................... 15

5. Filling Works .......................................................................................................................................... 16


5. 1. General ...................................................................................................................................................... 16
5. 2. Classification And Definition Of Fills ............................................................................................... 16
5. 2. 1. Fill Around Foundations ........................................................................................................ 16
5. 2. 2. Fill Around Direct Buried Cables ........................................................................................ 16
5. 2. 3. Fill Around Buried Piping ...................................................................................................... 16
5. 2. 4. Non Structural Fill ................................................................................................................... 16
5. 2. 5. Site Landscaping Structural Fill ........................................................................................... 16
5. 3. Preparation Of Fill Subgrade .............................................................................................................. 16
5. 4. Materials ................................................................................................................................................... 17
5. 5. Execution Of Fills ................................................................................................................................... 17
5. 5. 1. Method of Construction ........................................................................................................ 17
5. 6. Compaction ............................................................................................................................................. 18
5. 7. Filling-in Around Works ...................................................................................................................... 18
5. 8. Filling-in Of Trenches .......................................................................................................................... 18

6. Earthwork Finishing ............................................................................................................................. 20


6. 1. Gradient Adjustments .......................................................................................................................... 20
6. 2. Earthwork Leveling Adjustment ........................................................................................................ 20

C - CONCRETE STRUCTURES AND FOUNDATIONS SPECIFICATIONS................................... 21

1. Introduction ........................................................................................................................................... 21

2. Material Specifications ......................................................................................................................... 21


2. 1. General Principles .................................................................................................................................. 21
2. 2. Cement...................................................................................................................................................... 21
2. 2. 1. Specification ............................................................................................................................. 21
2. 3. Aggregates .............................................................................................................................................. 22
2. 4. Mix Water ................................................................................................................................................. 22
2. 5. Concrete Mix Requirements ............................................................................................................... 22
2. 6. Steel Reinforcement .............................................................................................................................. 23
2. 7. Concrete cover........................................................................................................................................ 24
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SPECIFICATION

Project: EPF-CPF construction

2. 8. Grouting for structures and equipment .......................................................................................... 24

3. TESTING .................................................................................................................................................. 25

4. ADMIXTURES .......................................................................................................................................... 27

5. FORMS ..................................................................................................................................................... 28
5. 1. General ...................................................................................................................................................... 28
5. 2. Design And Construction Of Forms ................................................................................................. 28
5. 3. Preparation Of Form Contact Surfaces ............................................................................................ 29
5. 3. 1. Cleaning And Oiling Of Forms ............................................................................................ 29
5. 3. 2. Re-use Of Forms ..................................................................................................................... 29
5. 4. Removal Of Forms ................................................................................................................................. 29
5. 5. Form Ties ................................................................................................................................................. 30

6. DESIGN CRITERIA FOR FOUNDATIONS.............................................................................................. 31


6. 1. Piles............................................................................................................................................................ 31
6. 2. General Design Requirements ........................................................................................................... 31

7. DESIGN CRITERIA FOR CONCRETE PAVING ...................................................................................... 36

8. HEALTH SAFETY SECURITY AND ENVIRONMENT ............................................................................ 37

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SPECIFICATION

Project: EPF-CPF construction

DEFINITIONS & ABBREVIATIONS

For the purposes of this document, the following definitions shall apply:

COMPANY MAZARINE Energy


PROJECT Flowlines and pipeline welding and installation
CONTRACTOR Party which carries out all or part of the WORK and Installation
of the Project. CONTRACTOR incorporates his approved
suppliers and subcontractors.
ENGINEERING COMPANY Engineering Management & Contracting (EMCO)
BIDDER Selected provider of the Elements, Subsystems or Systems.
Shall Indicates a mandatory requirement
Should Is to be understood as strongly recommended
May be Is to be understood as giving freedom of choice
WORK All construction activities of the defined elements as detailed
in the scope of work.
Approved Agreed and approved by COMPANY in writing.

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SPECIFICATION

Project: EPF-CPF construction

A - INTRODUCTION

1. Project Description
MAZARINE Energy, a private oil and gas exploration and production company, had been awarded the
rights to fully explore and develop new production facilities in the south of Tunisia under the
exclusivity of Zaafrane permit. By the end of the second quarter of 2015, MAZARINE had successfully
performed the drilling activities of two production wells CAT-1 and DGH-1.

In the frame of this project (further referred to as the PROJECT), MAZARINE, further referred to as
COMPANY, intends to develop and install its production facilities and export pipeline and that will be
executed on three main phases:

Phase-1: Laydown of DGH-1 well flow line and export pipeline


Phase-2: Installation of Early Production Facilities
Phase-3: Installation of Permanent Production Facilities

Figure 1 Key Schema of MAZARINE installations in South west of Tunisia

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SPECIFICATION

Project: EPF-CPF construction

2. General

2. 1.Scope

This specification covers the minimum requirements for the design of concrete foundations and
structures, platforms and building structures for the EPF-CPF CONSTRUCTION Project.

2. 2.Environmental Data

Refer to the Design Basis Document and to the Geotechnical Survey Report.

2. 3.Codes, Standards and Regulations

CONTRACTOR shall strictly comply with the Tunisian regulation (low, decrees, official orders related to
gas transportation systems) and applicable International rules and standards even though these are not
clearly specified in COMPANYs documents.
Unless otherwise specified, reference shall be made to the latest editions of the relevant rules and
standards, at the time the related contract will be signed.

2. 4.Civil & Structural Standards

NT 30.173 (2004) Actions sur les structures. Partie 1-1 : actions generales -
poids volumiques, poids propres, charges dexploitation des
batiments

NT 30.174 (2004) Charges dues a lexploitation dans les batiments


dhabitation et publics

NT 30.175 (2004) Principes generaux de la fiabilite des constructions


NT 30.176 (2004) Bases du calcul des constructions actions sismiques sur les
structures

NT 30.177 (2004) Bases du calcul des constructions - notations symboles


generaux
NT 30.178 (2004) Bases du calcul des constructions determination de la charge
de neige sur les toitures

NT 30.184 (2004) Bases de calcul et actions sur les structures. Partie 2- 3 :


actions sur les structures - charges de neige

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SPECIFICATION

Project: EPF-CPF construction

NT 30.185 (2004) Bases de calcul et actions sur les structures. Partie 2- 4 :


actions sur les structures - actions du vent

NT 30.180 (2004) Bases de calcul et actions sur les structures. Partie 2-2:
actions sur les structures - Actions sur les structures
exposes au feu

NT 26.05 (2004) Acier a beton pour armatures passives - Partie 2: Barres


nervurees

NT 26.05-1 (2010) Aciers pour larmature du beton - Partie 1: Barres lisses

NT 26.05-3 (2010) Acier a beton pour armatures passives - Partie 3: Treillis


soudes

NT 21.01 to 08 (1984) Aggregates for concrete

NT 21.18 to 31 (1990) Aggregates for concrete testing

NT 47.01 (2002) Cement specifications

NT 47.25/26/30/31/32 /33/34 Portland cement specification and testing

EN 1990 Eurocode 0: Basis of structural design

EN 1991 Eurocode 1: Actions on structures

EN 1992 Eurocode 2: Design of concrete structures

EN 1993 Eurocode 3: Design of steel structures

EN 1994 Eurocode 4: Design of composite steel and concrete


structures

EN 1997 Eurocode 7: Geotechnical design

EN 1998 Eurocode 8: Design of structures for earthquake resistance


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SPECIFICATION

Project: EPF-CPF construction

EN 10025 Hot rolled products of structural steels - Part 2: Technical


delivery conditions for non-alloy structural steels

ASTM C-191 Standard Test Methods for Time of Setting of Hydraulic


Cement by Vicat Needle

ASTM C227-10 Standard Test Method for Potential Alkali Reactivity of


Cement-Aggregate Combinations

ASTM C579 Standard Test Methods for Compressive Strength of


Chemical-Resistant Mortars, Grouts, Monolithic Surfacings,
and Polymer Concretes

ASTM C827 Standard Test Method for Change in Height at Early Ages of
Cylindrical Specimens of Cementitious Mixtures

NF A35-024 Steels for concrete reinforcement

BAEL 91 French Code for calculation of concrete

2. 5.Priority of Documents

In case of conflict between the documents attached to this SOW and the reference rules, codes and
standards, the following order of priority shall apply:
- Tunisian laws, decrees, ministerial orders and National industry requirements (such as
STEG, SONEDE, ONAS, TUNISIE TELECOM, etc.) .
- Project Specifications including COMPANY Specifications and Standards listed and
referred to within the Contract.
- International codes, standards, rules and regulations.

CONTRACTOR shall inform COMPANY about any conflict or inconsistency. It is important to mention
that in case of any conflict between anyone of the listed above documents the most stringent required
shall be applied.
COMPANY reserves the right to modify the above order of priority for particular matters.

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SPECIFICATION

Project: EPF-CPF construction

B - EARTHWORKS SPECIFICATION

1. Introduction
This section covers the general criteria regarding site preparation, earthworks, filling-in works, fill
materials and sub grade materials, to be performed.

2. Site Preparation

2. 1.Staking Out

2. 1. 1.General Staking Out


General staking out consists of marking on site the positions defined in the layout documents (axes for
each section) and all the points necessary for the project.

COMPANY shall supply CONTRACTOR with the documents required for this staking out operation.
CONTRACTOR shall proceed with the setting out of numbered stakes, which he shall solidly drive into
the ground, protect, maintain and replace if necessary.

CONTRACTOR shall arrange with COMPANY for staking out inspections.

2. 1. 2.Boundaries For Underground Networks


When works are to be carried out near underground networks, CONTRACTOR shall perform, after
COMPANY approval, a special marking along the location of the underground networks.

2. 2.Site Clearance

Preliminary site preparation concerns borrowing areas, storage and maintenance areas, site tracks and
works areas shall be defined by CONTRACTOR and submitted to COMPANY for approval.

Obstructions like gates, fences, trees, shrubs, stumps, roots, hedges and the like shall be taken down
or grubbed up and removed immediately from the site.

During the performance of these works, CONTRACTOR shall take all the necessary precautions to
ensure that overhanging lines, underground cables, conduits of any sort and nearby constructions are
not damaged.

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SPECIFICATION

Project: EPF-CPF construction

2. 3.Area Preparation For Earthworks

2. 3. 1.Scraping
CONTRACTOR shall carry out topsoil scraping over the project area. The scrapping (removal of topsoil)
shall be carried out according to its nature and thickness.

Deposit areas for topsoil shall be defined by COMPANY and CONTRACTOR shall insure good storage
conditions. Soil that cannot be used shall be disposed in waste areas. These works shall only be carried
out with COMPANYs approval and shall be checked.

2. 3. 2.Compaction Of Soil Under The Fill


All soils situated under the fill, having been scraped, shall be scarified; moisture conditioned and
compacted to an average density of 95% of the normal optimum proctor, with no individual test results
less than 90%.

In case the soil under the fill is made of compressible materials, measures shall be taken to ensure the
stability of the fill after COMPANYs approval.

2. 4.Earth Moving

CONTRACTOR shall submit within two (2) days prior to start-up of works any earth movement proposal
for COMPANY approval. This shall show the relationship between:
- Excavation and filling-in or deposits,
- Filling-in and excavation or borrowing.

The earth movement works shall meet with the following requirements:
- Topsoil coming from ground not suitable for reuse shall be permanently removed,
- Topsoil that is to be re-used on slopes shall be temporarily put aside and stored for later
use.

CONTRACTOR shall distinctly show in his earth movement program, two types of transportations:
- Transportation within the PROJECT,
- Transportation outside the PROJECT.

Wherever the deposit area may be, CONTRACTOR shall avoid running transport vehicles over topsoil.
After COMPANYs agreement on earth movement CONTRACTOR may undertake general earthworks.

Any modifications to actual earth movements in comparison to the program shall be made based on
COMPANY instruction following CONTRACTORs suggestion.
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SPECIFICATION

Project: EPF-CPF construction

2. 5.Pits, Quarries And Material Deposits

2. 5. 1.Investigation For Borrow Areas

When using borrow areas for earth, the following considerations shall be made:

- CONTRACTOR shall draw up a borrowing plan, which he shall submit for COMPANY
approval two days (2) before the respective material is borrowed,
- Criteria for the use of filling-in or excavated materials as defined in this specification are
applicable to borrowed materials,
- After borrowing operations, the borrow area shall not present any slopes of more than
1: 3 (Vertical: Horizontal), subsidence or ditches.
- The topsoil from excavation shall be re-spread uniformly over the area. The final
arrangement shall be submitted to COMPANY approval.

2. 5. 2.Provisional Deposits
The height of provisional deposits is limited to 3 m.

The positioning of these provisional deposits shall be arranged in agreement with COMPANY and
preferably free PROJECT areas shall be selected. They shall not hinder water flow.

2. 5. 3.Permanent Deposits
CONTRACTOR shall be responsible for all permanent deposits. This applies not only to soils that are
not suitable for re-use as fill-in material but also for excess soil.

Site areas where project works are not to be undertaken may possibly be used for such deposits. This
shall depend on COMPANYs approval and on the condition that the deposits do not hinder water flow
and drainage structures.

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SPECIFICATION

Project: EPF-CPF construction

3. Excavation Works

3. 1.General

This chapter covers the definition of the types and methods of excavation.
The material and methods of execution shall take into account the geological and geotechnical
conditions of the soil in the site area.

3. 2.Definition Of Excavation Types

3. 2. 1.Top Soil Removal


Topsoil removal means the excavation made along the ground profile to an average depth of 0,20 m
below ground level, in soils of any nature and consistency excluding rock, to remove the superficial
soil layer. Topsoil removal also includes clearing of bush, grass, shrubs, and other unsuitable material
(for example debris); this material shall be removed using the same mechanical equipment as for
topsoil removal.

3. 2. 2.General Excavation
General excavation means excavation made at any depth, with a horizontal surface area greater than
150 m and a minimum width of 3,50 m.

General excavation is carried out for grading and leveling of construction areas, for cutting of
embankments, for construction of yards, roads, channels, ground bearing floors, basements, pipe ways
etc., for foundations of cylindrical vertical tanks, etc.

3. 2. 3.Limited Section Excavation: Trench excavation


Trench excavation means limited section excavation for laying of concrete trenches, sewers,
aqueducts, pipes and ducts in general, electric and instrument cables, etc.

3. 3.Definitions Of Excavation According To The Soil Nature

3. 3. 1.Earth Excavation
Earth excavation means any excavation in soil of any nature and consistency, which can be carried out
without the use of a ripper, even in the presence of stones provided the volume of individual stones
does not exceed 0,50m.

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SPECIFICATION

Project: EPF-CPF construction

3. 3. 2.Soft Rock Excavation


Soft rock excavation means any excavation in soft rock with uniaxial compressive strength less than
25MPa. These rocks can normally be broken by suitable mechanical means and/or by ripper single cut.

3. 4.General Instructions

Unless otherwise specified, earthworks shall be carried out mechanically by CONTRACTORs selected
methods. CONTRACTOR shall provide COMPANY with a list of dedicated equipment.

If during works, slopes are not consistent with ground characteristics or if excavation stability is not
insured, CONTRACTOR shall inform immediately COMPANY and take measures in case of emergency.

Any over-excavation will be refilled at CONTRACTOR expenses according to present specifications.

3. 5.Methods Of Excavation

3. 5. 1.Requirements
The requirements in this specification apply whichever the geological soil nature may be and in the
presence or not of water.

All excavations shall comply with the sizes and elevations indicated in the drawings.

The works shall be set out in accordance with the lines, levels and slopes indicated on drawings.
The bottoms of foundations excavations shall be made horizontal and/or levelled. The compaction of
excavation bottoms and of backfilling relevant to limited section excavation or general excavation shall
be in accordance with the lines, levels and slopes indicated on construction drawings.

Roots, shrubs, debris, plants, etc. from topsoil removal shall be transported to dumping areas.

3. 5. 2.Tolerances
Tolerances on finished excavation, for dimensions, elevations and positioning specified on drawings,
shall be as follows:
- Excavation bottom elevation +20 /-50 mm,
- Excavation centerline (for limited section excavation) +40 /-40 mm.

3. 5. 3.Use Of Excavation Materials


The use of materials from excavation, which are considered suitable for immediate backfilling or their
transportation to temporary storage for subsequent use, shall comply with the work schedule.

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SPECIFICATION

Project: EPF-CPF construction

If the material from excavation is not used immediately for backfilling, it shall be deposited into a
proper area inside the plant area and/or construction site, for later use.

The materials which cannot be re-used or are considered unsuitable for other works shall be dumped
in an authorized area outside the plant.

4. Drainage and Dewatering


CONTRACTOR shall prevent surface or subsurface water from entering the excavations and from
flooding the site.

If so indicated in the geotechnical survey report that dewatering may be necessary, CONTRACTOR shall
provide labour and equipment and a method statement for approval by COMPANY of how water
entering excavations is to be removed and disposed of.

CONTRACTOR is fully and solely responsible for the design, installation, operation and de-
commissioning of any dewatering required.

CONTRACTOR shall take suitable precautions to Pumping and bailing from the interior of any
foundation enclosure shall be done in such a manner as to prevent the possibility of movement of
water through or alongside any concrete being placed. Excavations shall be as dry as possible prior to
and during placing concrete.

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SPECIFICATION

Project: EPF-CPF construction

5. Filling Works

5. 1.General

This chapter covers the methods of execution and finishing of fill and/or embankment
All fill materials shall be subject to approval by Company.

5. 2.Classification And Definition Of Fills

5. 2. 1.Fill Around Foundations


Suitable soils shall be the same as specified for subgrade fill except that the fill shall be well graded
with a maximum particle size of 20mm.

5. 2. 2.Fill Around Direct Buried Cables


The first 100mm of fill around cables shall be suitable sand with a maximum of 5% passing by weight
passing a 0.075mm sieve, and no retention on a 4.75mm sieve.

Fill outside of the first 100mm may be as subgrade fill.

5. 2. 3.Fill Around Buried Piping


The first 150mm below and 300mm around and above the pipes shall be suitable sand or fine granular
material, easy to compact, and contain no coarse particles that could damage the pipes.

Fill above the first 300mm may be as subgrade fill.

5. 2. 4.Non Structural Fill


General fill and fill that will not be required to carry structural loads may comprise un-sorted
excavated soils providing that they contain no unsuitable material as described in Section 5.0.

5. 2. 5.Site Landscaping Structural Fill


The site(s) finished ground surface finish shall consist of 100mm compacted thickness subgrade fill.

5. 3.Preparation Of Fill Subgrade

Before the execution of fill, the ground forming the sub grade shall be compacted to 95% maximum
dry density unless otherwise indicated on construction drawings.

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SPECIFICATION

Project: EPF-CPF construction

5. 4.Materials

Unacceptable material:
- Peat, organic clay or silt, wood or other material subject to decomposition,
- Silt defined for this purpose as soil having 80% or more of material in the particle size
range 0,06-0,002 millimeters,
- Material in a frozen condition,
- Clay having a liquid limit exceeding 90% and /or a plasticity index exceeding 65%,
- Clay or generally plastic material which has water content exceeding the plastic limit plus
2%,
- Any material which cannot be compacted in accordance with the compaction
requirements,
- All materials having a Moisture Condition Value (MCV) of 9 .

5. 5.Execution Of Fills

5. 5. 1.Method of Construction
The fill material shall be laid in layers of thickness proportional to the nature of the material used and
the method of compaction. Where hand tamping equipment is used, the maximum uncompacted
thickness of each layer shall be 0,15m; where mechanical rolling equipment is used; the maximum
uncompacted thickness of each layer shall be 0,30m.

Prior to placing fill, the upper 15 cm shall be scarified and compacted as specified herein.
Where the fills are made of rocks, they shall not have any dimensions exceeding 2/3 of the thickness
of the compacted layer.

All voids between rocks shall be filled with graded granular material free of silt, clay and organic
material, so as to obtain a compacted mass.
The larger size rock fragments shall be spread uniformly in the lower part of the fill and those with size
less than 100mm shall be kept for the upper layers.

Each layer shall be compacted to at least 95 % of its modified Proctor maximum dry density in
accordance with ASTM D1557.

Field density tests of each layer of compacted soil shall be taken with sufficient frequency to be
representative of the fill as a whole.

All field density tests shall be made in accordance with ASTM D1556 or ASTM D2922.

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SPECIFICATION

Project: EPF-CPF construction

Embankment fill shall be carried out with regular and smoothed slopes having well shaped and aligned
edges.

CONTRACTOR cannot continue the work without COMPANYs approval, of the previous compacted
layer.

Consolidation of fill by water flooding or water jetting shall not be used without a specific written
approval of COMPANY.

5. 6.Compaction

Compaction of fill and backfill shall be as follows unless otherwise specified:


- Compact to 95% maximum density per ASTM D1557.
- Gravel and other large materials not adaptable to density tests shall be well compacted
as approved by COMPANY.
- Lesser degrees of compaction shall be used where the specified compaction density
would be injurious to the buried structure or piping, and with the approval of COMPANY.
- In-place density shall be determined by one or more of the methods given by ASTM
D1556, D2167, D2922, and D2937.
- All fill which does not meet the compaction requirements shall be re-compacted or
removed and replaced.

5. 7.Filling-in Around Works

These filling-in works shall be made around and along buried works, which have been protected
previously.
Boulders, lumps of concrete and other foreign matter shall be excluded.
This filling-in shall be compacted by means of pneumatic rammer, proposed by CONTRACTOR and
approved by COMPANY. Heavy compactor shall be excluded.

Care shall be taken during back-fill operations to prevent damage to permanent works.
In particular, damage to waterproof membranes and other concrete protection shall be repaired before
back filling is resumed.

5. 8.Filling-in Of Trenches

Filling-in of trenches opened up for laying cables or conduits, covered with RED sheet, shall be carried
out with materials that have been cleared of stones.

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This filling-in shall be carried out with selected fill-in material. Layers with direct contact with a cable
or a conduit shall be cleared of any element more than 5 cm in size.

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6. Earthwork Finishing

6. 1.Gradient Adjustments

Excavation gradients shall be in accordance with the slopes and tolerances defined in the project,
particularly in the case of rocky ground.

The surfacing to be applied shall also be taken into consideration. The grades shall be carefully cleared
of stones and broken rock that are not stable.

6. 2.Earthwork Leveling Adjustment

Levels checking shall be made by CONTRACTOR from the planted stakes, according to COMPANY
approved layout plan. Variations found at each point in comparison to the prescribed dimensions shall
remain within the defined tolerance.

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C - CONCRETE STRUCTURES AND FOUNDATIONS SPECIFICATIONS

1. Introduction
This specification covers the minimum requirements for the design of concrete foundations and
structures, platforms and building structures.

2. Material Specifications

2. 1.General Principles

Materials and products to be used for the construction works shall be supplied by CONTRACTOR and
submitted to COMPANY for approval.

Any modification of the requirements listed for the different materials shall be subject to COMPANY's
approval.

Materials shall be delivered with appropriate documentation/certificates.

If not documented properly, materials shall be submitted to tests:


- Composition or approval tests,
- Operational tests,
- Acceptance tests.
If not approved by COMPANY, the materials Shall be rejected and Shall be removed from the site or
sorted in a clearly marked area for rejected materials.

2. 2.Cement

2. 2. 1.Specification
Ordinary Portland cement used for construction work shall meet the provisions of the following
standards and above listed national standards:
- normal cement: ENV 197/1
- sulphate resistant cement: UNI 9156
- washing resistant cement: UNI 9606

Rapid hardening cement shall not be used.


Cement storage temperatures shall be monitored and preventative measures (evaporative cooling) shall
be taken to ensure that cement temperatures do not exceed 35C.

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2. 3.Aggregates

All aggregates for use in the making of concrete shall meet the provisions of ISO/DIS standard 4847.2
and above listed national standards. Coarse aggregates shall be limited to 20 mm nominal size for all
grades of concrete.

Aggregates shall be clean, hard, durable, chemically inert and impermeable. They shall be free from
adherent coatings, laminated particles or admixtures of materials likely to be deleterious to the
concrete.

Dune, desert and beach sand shall not be used in the making of concrete.

2. 4.Mix Water

Mix water shall comply with the recommendations of EN standard 1008 relevant to concrete mixing
and relevant Tunisian standards.

Sulphate, alkaline carbonate and bicarbonate contents, not specified on above mentioned standard,
shall not exceed the following values:
- Sulphates (SO3): 1 g/l (1000 p.p.m.)
- Alkaline carbonates and bicarbonates: 1 g/l (1000 p.p.m.)

2. 5.Concrete Mix Requirements

The proportions of cement, aggregate and water shall be such as to meet the required strength as
used in the design of the concrete section, to be adequate for the exposure conditions, to achieve the
desired workability and comply with the requirements of this specification. Hand mixing of concrete
shall not be allowed.

Grades of concrete for various structures and foundations shall be in accordance EN 1992.
In accordance with NT.47.01, cement strength shall comply with the following Table

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Table 4-1: Resistance classes according to NT.47.01

Resistance class Compression resistance (MPA) Stability (expansion)


mm
2 days 7 days 28 days
32.5 N 16 32.5(30) 52.5
32.5 R 10 (8) - 32.5 (30) 52.5
10
42.5 N 10 (8) - 42.5 (40) 62.5
42.5 R 20 (18) - 42.5 (40) 62.5
52.5 N 20 (18) 52.5 (50) -
52.5 R 30 (28) 52.5 (50) -

Values between ( ) are limit values


N: Normal hardening Cement
R: Fast hardening cement
The minimum grades of concrete for the various works shall be as specified below.

2. 6.Steel Reinforcement

Reinforcing steel shall be B450 or above listed standards with a characteristic yield stress equal to 450
N/mm.

Immediately before concrete is placed, all reinforcing steel shall be free from loose mill scale, loose
rust, oil, grease, paint or any harmful matter that may decrease the bond between the steel and the
concrete.

The clear distance between individual bars shall not be less than:
- 1.3 times the maximum size of the coarse aggregate
- Twice the diameter of the bar or the diameter of the immersion vibrator
- 50 mm for bars in walls

The center-to-center distance of individual bars shall not be more than:


- 150 mm - For main bars in beams where bending moments are maximum.
- 250 mm - For bars in slabs.
- 250 mm - For bars in walls.
- 250 mm - For mild steel stirrups in beams.
- 300 mm - For longitudinal bars in columns.
- 300 mm - For horizontal side bars in beams.

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- 300 mm - For high yield stirrups in beams.


- 400 mm - For any other bars not mentioned above, provided the cross bars are spaced at
not more than 250 mm.

2. 7.Concrete cover

Protective layer of concrete shall meet the provisions of EN 1992.

The cover to reinforcement shall be measured as the minimum (including for example, links) distance
between the outside of the outermost reinforcement, and the nearest finished surface of the concrete
members (excluding finishes). The position of reinforcement should be checked before and during
concreting, and particular attention given to maintaining the cover within the limits specified.

The following minimum concrete covers to reinforcement shall be observed unless otherwise shown on
the drawings:

- Formed concrete below ground 75 mm (including plinths)


- Concrete exposed to weather 50 mm
- Ends of reinforcing bars 50 mm or twice bar diameter, if greater
- Suspended floor and roof slabs 35 mm
- Grade slabs 50 mm
- Internal column faces 35 mm
- Internal beam faces 35 mm
Maximum cover to reinforcement shall be the minimum as specified above plus:
- 5 mm on bars up to and including 12 mm diameter
- 10 mm on bars over 12 mm and up to and including 25 mm diameter
- 15 mm on bars over 25 mm diameter

2. 8.Grouting for structures and equipment

Grout shall be used under all base plates of equipment and structures, where a uniform bearing
surface is required for the transfer of loads into the foundation. Grout shall be non-shrink cement
based or epoxy based grout.

The minimum grout thickness shall be 25 mm unless otherwise required. Towers, compressors and
base plates 500x500 or larger shall have a minimum grout thickness of 40 mm.

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3. TESTING
Concrete mix must be tested in accordance with the relevant specifications. Testing shall include the
following:
Slump: the slump of the structural concrete mixes shall be such that the concrete can be transported,
placed into the forms, and compacted without segregation. The design slump shall be verified by the
trial mixes, according to EN 12350.

Total Salt content:


a) Chlorides
The total chloride content of the concrete from all sources, expressed as the percentage of chloride
ions by mass of cement (calculated according to EN 206-1), shall not exceed 0.20%.

b) Sulphates.
The total sulphate content of the concrete from all sources, expressed as SO3, shall not exceed 4% by
weight of dry cement. The sulphate content shall be calculated as the total from the various
constituents of the mix.

Water/Cement ratio: the maximum free water/cement ratio shall be in accordance with Section 4.4. The
water/cement ratio shall be continuously checked at the mixer with due allowance being made for
water (if any) contained in the aggregates.

Compressive strength: Concrete shall be sampled and tested for compressive strength in accordance
with EN 12350.

Samples for production concrete cube tests shall be taken at the average rate of one per 50 m of
concrete placed, with a minimum of one sample taken every day that the mix is used. For concrete
structures containing less than 50 m of concrete placed in a single session, at least one sample shall
be taken. The temperature of the fresh concrete for each sample shall be recorded. A sample consists
of three cubes.

Samples shall be taken at the point of placement in accordance with EN 12350. From each sample four
150 mm cubes shall be made, one for testing at 7 days after casting and two for testing at 28 days and
one reserve at 90 days. All samples shall be clearly marked with their identification and accurate
records shall be supplied to the Company giving:
- Identification of test cube.
- Date and time of sampling.
- Mix designation.
- Location of sampled batched after placing.
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- Method of compaction.
- Date of testing.
- Cement type and country of origin.
- Volume of pour.
- Age of sample in days.
- Weight of sample in grams.
- Density in kg/m.
- Crushing load in Newton.
- Crushing strength N/mm.
- Signature of person preparing cube.
- Signature of person crushing cube.

Acceptance of concrete shall be per BS EN 206-1.

The contractor shall give the Company timely notice of work ready to be tested or inspected and the
date and time arranged so the Company may observe the testing or inspection.

Certified copies of all test certificates and reports prepared by the Contractor shall be submitted direct
to the Company.

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4. ADMIXTURES
Admixtures shall only be used if specified or approved by the Company in writing, subject to the
following conditions:
- Used in strict accordance with the manufacturers instructions.
- Dosing shall be automatically controlled at the mixing plant.
- Proprietary accelerating, retarding and water-reducing agents shall comply with the
requirements of EN 480.
- Admixtures containing chlorides shall not be used.
- Pigments shall comply with the requirements of EN 12878.
- Additives shall be in liquid form.

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5. FORMS

5. 1.General

Three types of forms May be used:


- Ordinary, made of wood boards, parallel with sharp edges. Wood boards may result from
rough sawing. Joints between boards shall be less than 1 mm.
- Smooth, made of planed wood boards on the four sides, parallel with sharp edges. Joints
shall be less than 0.5 mm and carefully treated (adhesive tapes). Form panels may also
be made of plywood or iron plates.
- Well-finished, made of plywood, possibly with a plastic coating, or of well planed iron
plates. Joints shall be less 0.5 mm, carefully plugged with a suitable filling and
smoothed. (Adhesive tapes not accepted). No projection shall be accepted along with the
joints. No tie holes visible.
- Steel forms shall be suitably treated to prevent rusting of the face to be in contact with
the concrete as well as for the final surfaces to be of a good quality and shiny finished.
Steel plates are to be made of galvanized steel and fastened to formwork to maintain
proper alignment until concrete is in place.

Forms shall be of reliable construction and safe for both workers and public; they Shall be sealed
against leak or loss of grout, rigid, plumb, well braced and interconnected to prevent any warping or
displacement.

5. 2.Design And Construction Of Forms

Forms must be strong enough for supporting, without deflection, concrete consolidation and also dead
or live loads to which they might be subjected. CONTRACTOR shall provide all precautions to ensure
safe working conditions during all kinds of weather.

Inspection openings shall be provided at the base of the forms or other locations to facilitate cleaning,
observation within forms of placement and vibration of concrete.

Concrete finishing on these opening areas shall be stipulated in particular specifications.

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5. 3.Preparation Of Form Contact Surfaces

5. 3. 1.Cleaning And Oiling Of Forms

All form surfaces and inserts shall be cleaned of any trace of mortar or other foreign matters before
concrete is being placed.

The bottom of molds shall be carefully blown out with compressed air.

The surfaces of the forms shall be oiled to effectively prevent sticking and will not stain the concrete
surface.

5. 3. 2.Re-use Of Forms
Re-usable forms shall be designed and maintained so that the quality of concrete surfaces complies
with specifications and meets COMPANY approval.

5. 4.Removal Of Forms

Forms shall be removed in such a way to provide full safety of the structure according to concrete test
results.

All precautions shall be taken to avoid damages the concrete surfaces.

Forms used for concrete curing purpose shall not be removed before the curing period has expired.
Time for removal of forms shall be submitted for COMPANY approval.
Under average weather conditions (15C.) the following table will give a guide to the minimum periods
after casting at which forms and supports can be removed:
- Vertical formwork to columns walls and large beams 24 hours
- Soffit formwork to slabs 7 days
- Props to slabs 14 days
- Soffit formwork to beams 14 days
- Props to beams 21 days
For concrete made with rapid hardening Portland cement, these times may be reduced according to the
approval of COMPANY.

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5. 5.Form Ties

The material and position of any ties passing through the formwork shall be submitted to COMPANY
approval.

Any holes left after removal of ties shall be filled with concrete, mortar or approved composition.

Use of embedded wire ties for holding forms shall not be permitted in concrete walls to be subjected
to water pressure or where the surfaces through which the ties extend will be permanently exposed.

Wire ties may be used for holding forms for concrete walls where embankment is to be placed against
both sides of the walls.

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6. DESIGN CRITERIA FOR FOUNDATIONS

6. 1.Piles

The main function of bearing piles is to transfer the loads on a foundation to deeper (soil) strata which
are capable of carrying such loads, in such a way that:
- An adequate safety factor against loss of stability is provided.
- The foundation settlement/deformation is less than the allowable values of the
foundation and the equipment supported.

The design and testing of piles shall take into account both short-term and long-term behavior of the
pile foundation.
Piles shall be designed and checked according to EN1997:2005.

For piles axial and lateral load capacity reference shall be made to the Geotechnical Report.

6. 2.General Design Requirements

a) Steel Piles
Shapes for steel piles shall be limited to pipe material, unless otherwise specified all structural steel
pipes shall be Grade A 53 to ASTM.

Protective coatings where required, shall be indicated on the drawings.

Surfaces due to receive a protective coating shall be blast cleaned, prior to application of the coating,
which shall then be applied in accordance with the Manufacturers instructions.

At the joints the steel piles shall be prepared for full penetration welds, prior to welding the pile
elements shall be aligned to meet the required tolerances.

All welding shall be in accordance with the applicable specifications and be executed by certified
welders. After welding the splice shall be subject to a non-destructive examination.

b) Prefabricated Concrete Piles


The concrete mixes shall be C45/55, and the reinforcing steel with a minimum characteristic yield
strength of 450 N/mm.
The cover to reinforcement, including binding wire, shall not be less than 40 mm for fully embedded
piles in the ground and not less than 50 mm for piles installed in or above open water.

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Welded joints: a lap shall be formed by stripping reinforcement of surrounding concrete for a distance
of forty times the diameter of the longitudinal bars. They shall be thoroughly cleaned and all lateral
reinforcement removed.

Additional reinforcement shall be placed in position, securely fixed or welded to main bars and the pile
extended by concreting in properly formed molds to the required length.
Joint with steel coupling: non-prestressed concrete pile elements may be lengthened by using
approved and certified steel couplings.

c) Prestressed concrete piles


Characteristic yield strength of 450 N/mm.

The cover to reinforcement, including binding wire, shall not be less than 40 mm for fully embedded
piles in the ground and not less than 50 mm for piles installed in or above open water.
Prestressing steel shall be in accordance with EN 10138.

Welded joint: a lap shall be formed by stripping reinforcement of surrounding concrete for a distance
of forty times the diameter of the longitudinal bars. They shall be thoroughly cleaned and all lateral
reinforcement removed.

Additional reinforcement shall be placed in position, securely fixed or welded to main bars and the pile
extended by concreting in properly formed molds to the required length.
Joint with steel coupling: prestressed concrete piles may only be lengthened using approved and
certified steel coupling.

d) Shallow Foundations
Shallow foundations shall be designed and checked according to EN1997:2005. The following ultimate
limit states shall be considered:
Loss of equilibrium of the structure, considered as a rigid body. The following inequality shall be
satisfied:

Mdst Mstb;
where Mdst is the design value of the destabilising bending moment, and Mstb is the design value of
the stabilising bending moment, both calculated using the partial factors given by EN1997.
Failure by sliding.

Foundations shall be checked against failure by sliding on the base, the following inequality shall be
satisfied:
Fdst Fstb
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where Fdst is the design value of the destabilising force, and Fstb is the design value of the stabilising
force, both calculated using thepartial factors on actions (f) and on soil parameters (m) given by
EN1997.
For the design friction angle between soil and concrete refer to the Geotechnical Report.

Bearing resistance failure.


Bearing resistance failure shall be checked verifying that Vd/A Rd/A. Where Vd is the design vertical
force on the foundation, Rd is the design bearing resistance of the foundation and A is the reduced
contact area, calculated according to Meyerof Method. Both Vd and Rd shall be calculated using the
partial factors given by EN1997.

In the geotechnical report the allowable pressures on soil, based on the above stated limitations for
different sizes of foundations, will be defined.

Account shall be taken of displacements caused by actions on the foundations. Excessive deformations
shall be avoided. Refer to the geotechnical report for indications regarding the evaluation of shallow
foundations settlements.

e) Foundation slabs for exchangers and horizontal vessels


All exchangers for which bundle pulling is foreseen shall be designed for a longitudinal force, acting at
the exchanger axis, to be assumed equal to 100% of bundle weight; in presence of extraction screws
this force can be assumed equal to 50% of bundle weight.

The tube bundle pull-out load shall be resisted by one pier (fixed saddle pier). When exchangers are
placed one upon the other, only the bundle pull-out of the bundle section that produces the worst
condition shall be considered.

Saddle design shall be carried out for the more loaded saddle (fixed saddle).
Concrete gross section and reinforcement shall be the same for sliding and fixed saddle.
The sliding plate anchors bolts shall be verified for transversal exceptional loads (wind, earthquake,
etc.).
Adequate stiffness steel plate will be performed in the sliding saddle when Teflon pads are provided.

f) Foundations of vibrating machines


The machines Manufacturer will provide the following basic information:
- An arrangement drawing showing overall dimensions of the required concrete support
for the machines, with location and size of opening, holes and grooves; location of
baseplate with overhanging machines, pads, anchor bolts and relevant pocket sizes.

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- A layout showing location of auxiliary equipment and miscellaneous, such as condenser,


piping supports and service platform legs.
-
- A drawing showing distribution lines to be connected to the footing or passing through
it.
- The operating speed range of each machine.
- The shaft position, both in plane and in elevation.
- Weight and center of gravity for every machine and base plate and the static load acting
on each support.
- Weight and center of gravity of each rotating mass (for rotating machinery only).
- For each machine the standard dynamic forces and moments with relevant point of
application and phase angle.
- Indication of supports where dynamic load acts.
- Full load torque and force produced upon each support.
- Short circuit moment and force produced upon each support.
- Depression on the condenser and type of connection (rigid or flexible).
- Permissible amplitudes of vibration, allowable settlements and any other requirement
that, according to the Supplier, is to be taken into account.

Design criteria

Foundations for vibrating machines must be isolated from adjacent foundations of buildings,
structures and equipment by a through joint; if special cases occur, as for example when the distance
between machineries is smaller than the necessary dimension for the single foundation, it is possible
to position more machineries on the same foundation, at the only condition that the machineries are of
similar type and after verifying that the foundation can be considered as a rigid block.

As a rule, the depth of foundations beneath the ground should be chosen so that good bearing strata
can be reached, but it should also be taken to a minimum in order not to increase overturning effects.
Immediately upon completion of the excavation a blinding layer of plain concrete shall be placed to
prevent deterioration of the ground formation and provide a sound clean working surface for the
construction of the foundation structure. The extent and thickness of the blinding shall be in
accordance with the recommendations in the Geotechnical Report.

Vibrating machineries directly coupled with each other must be placed on the same foundation.
Expansion joints must be avoided on foundation block or structure.

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Normally, foundations for vibrating machineries should be detached from paving by a 25 mm wide
joint as a minimum.

The clearance between the periphery of the anchor bolt pockets and the nearest external surface of
concrete must not be less than 100 mm.

speed of the machinery itself (high-tuned foundations), the pile loads or soil bearing pressures shall
not exceed 50% of the design values for static loads. Otherwise (low-tuned foundations), the pile loads
or soil bearing pressures shall not exceed 75% of the design values for static loads.
For block-type foundation of light machines (centrifugal machines with Machines+ Motor+Steel Base
less than 40 kN) placed on the ground the concrete weight will be the minimum of :
3 times the weight of the machineries, in the case of rotating machines or balanced reciprocating
compressors.
5 times the weight of the machineries in the case of unbalanced reciprocating compressors or
pumps.

The maximum eccentricity between the center of gravity of the machine-foundation system and the
center of gravity of the base surface should not be more than 5% of the dimension of the base area in
that direction.

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7. DESIGN CRITERIA FOR CONCRETE PAVING


All paved areas exposed to spillage of oil or chemicals shall be provided with a reinforced concrete
slab.

The paved drainage area shall be divided into areas having a size of not more than 400 m and sloping
(1.0% min. and 3.33% max) to a pit connected to the oily water sewer system; an area 2 m in diameter
around the drain shall be sloped 5% minimum.
There will be two types of reinforced concrete paving:
a) In lightweight areas the paving shall have, as a minimum, the following characteristics:

- 160 mm thickness;
- a welded wire fabric reinforcement, 200x200x7 mm, weighing not less than 3.02
kg/m, put at 50 mm from top surface.
b) In heavyweight areas exposed to the movement of maintenance equipment, paving shall have
as a minimum the following characteristics:

- 200 mm minimum thickness.


- a double layer of welded wire fabric reinforcement 200x200x7 mm.

Special attention will be paid to curing because of the weather conditions; curing by moisture retention
is recommended using a polyethylene film or other plastic membranes, to be used for covering fresh
concrete.
The concrete surface in contact with the soil will be protected by a layer of polyethylene sheet
underneath the paving.

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8. HEALTH SAFETY SECURITY AND ENVIRONMENT


The Contractor shall comply with Tunisian HSSE regulations and Company standards.

The Contractor shall provide for Company approval an HSSE plan covering site rehabilitation works.

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