PT.

KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 2 of 15
OPERATING PROCEDURE Revisi : 0

1. General

The following procedure covers batch plant operation which will comprise: ordering procedure,
concrete production and delivery; material and production control, product quality control,
personal and record systems.

I. PROCEDURE OF ORDERING CONCRETE

In order to supply of the required quality in the concrete location at the required time,
PT. Karinda Daya Perkasa (PT. KDP) will request PT. Chiyoda International
Indonesia (PT. CII) for appropriate arrangement of details of concrete pouring demand
schedules and detailed time frame for concrete production.

General/ Overall Programs

Three Monthly Demand Schedule

Concrete demand schedule/ construction period which will show monthly concrete
requirement for three month, estimate date and start of production, type class of concrete
required each month, the date of peak demand concrete requirement, layout of pouring
location and other necessary information should be provided by PT. CII to PT. KDP in
order to allow time to arrange material delivery schedules and other required equipment.

Weekly Demand Schedule

Should be provided by PT. CII to PT. KDP to show quantity and quality of required
concrete each day in a week. Concrete demand more than 100 M3 in one day shall be
conformed 1 (one) week before.

Daily Demand Schedule

The confirmation of concrete production each day should be given to PT. KDP Batching
plant office at least one day (24 hours) before the start of the production and PT. KDP
will provide specials order form for placing order to indicate the following:
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 3 of 15
OPERATING PROCEDURE Revisi : 0

Order form number

Name of contractor/ client
Job site/ pouring location
Date/ time of start of delivery
Speed of delivery/ internal between trucks
Total quantity of required order
Class of concrete & type of cement
Maximum aggregate size
Specified slump/ workability
Type of specified admixture and amount
Required tests and other necessary information as required

II. CONCRETE PRODUCTION DELIVERY

A. Basis of Supply measurement

Measurement of concrete supply will be by cubic meter of fully compacted fresh

concrete. The volume of a given batch divided by the weight per cubic meter of
concrete or can be calculated as the sum of the weight of all material used,
including water. Minimum order shall be 0.5 (half) Cum. meter with minimum
additional order shall be 0.5 (half) Cu. meter.

B. Raw Materials for Concrete Production and Storage

Raw materials used for the concrete shall meet the specification requirements
and be subjected to PT. CII/ PT. PetroChina International Jabung Ltd (PT.
PCI Jabung Ltd) approval.

Cement

The cement used in producing the concrete shall meet the specified
requirements (what ever specified), of ASTM C 150 for type I and type II
cement.

All cement is stored in the cement Warehouse, protected from water and other
weather condition, while at the time of concrete production. Cement will be
transferred to the storage bin at batch plant by screw conveyor prior to mixing.
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 4 of 15
OPERATING PROCEDURE Revisi : 0

Aggregate

The aggregate used for the concrete conforms with ASTM C.33, i.e. river
or crushed gravel with maximum size inch graded aggregate, sieve size 37.5
mm, armor stone, compacted gravel and washed (natural) sand. Aggregate to be
placed separately in the stock pile in such way that contamination, intermingling
with adjacent material is avoided. Cleaning of aggregates will be done
periodically, preferably during night time or no pouing to have enough time for
water to drain.

Water

The water used for the concrete is supplied from PT. CII/ PT. PCI Jabung Ltd
designated desalination plant and stored inside the water tank available at batch
plant. The water shall meet the specified requirements of ASTM C.94.

Admixture

Used admixture is liquid form Daratard 40 retarder which conforms to ASTM

C.494 type D and Daracem RM Superplasticizer which conforms to ASTM
C.494, C.1017 tyep D and G.

Retarder will be added at the batch plant and mixed with water during batching
process. Superplasticizer will be added at site to allow for better slump/
workability retention. PT. KDP will install dispenser at the batch plant and will
provide container/ graduated cylinder for measuring Superplsticizer at site.
Admixtures/ additives shall adhere to the following requirements:
Be compatible with the type of cement used
Have no adverse effect on the durability, shrinkage and water tightness
properties of finished concrete
Contains less than 0.05 % chlorides
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 5 of 15
OPERATING PROCEDURE Revisi : 0

C. Plant and Equipment

The typical batch plant to be provided by PT. KDP is an automatic wet process
batching plant assuring that high consistent quality and uniform concrete
materials including water are mixed with paddle pan type mixer before being
discharged in to the truck.

The function of truck mixer is as an agitator to transport concrete which has

been mixed at the batch plant. In transit the drum of the mixer rotates slowly at
about 1 or 2 revolution per minute just to keep the concrete agitated and turning
over. When the truck arrives on site the drum shall be speeded up to about
10~15 revolution per minute at the fast speed and the mixing time to be arranged
to maximum uniformity of the concrete.

PT. KDP indents to use six (6) truck mixers for the project with average capacity
of six (6) cubic meters per truck, while the capacity of PT. KDP Batch Plant is
fourty five (45) cubic meter per hour. One (1) batching plant will be fully
operated to be able to supply the maximum requirement of the project. To
supply concrete continuously whitout any any shutdown of the batching plant,
PT. KDP should be mobilized one (1) batching plant by capacity fifteen (15)
Cu.m as back up supply in case of the shutdown.

D. Measurement of Materials and Records

All raw materials used for the concrete i.e. cement aggregates and water will be
measured by weight with admixture to be measured by volume using dispenser
or container/ graduated cylinder at known volume.

During the concrete production at the batch plant, fine and coarse aggregate will
be stored separately according to the size of material and weighed individually
into the size of material and weighed individually into the hopper to guarantee
maximum uniformity of the concrete. Before the start of weighing materials all
the scales shall be adjusted to zero.
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 6 of 15
OPERATING PROCEDURE Revisi : 0

Accuracy of Scale

The scale divisions used to measure the raw materials are divided into the
following:

Range of Scale Division Accuracy

Cement 600 kg 1 kg + 0.2 %

Aggregate 2.500 kg 5 kg + 0.2 %
Water 250 kg 1 kg + 0.4 %

When the amount of batched is less than the capacity of truck being loaded, PT.
KDP will provide a special form to record each quantity of materials used in
each mix at the time of batching, indicating :

Contractor, pour location, truck number, time of batching, time of loading, class
of concrete, maximum aggregate size and weight of each material batched.

E. Documentation/ Delivery Ticket

Before discharging the concrete at the point of delivery, PT. KDP will provide a
delivery ticket for each batch of concrete detailing the following information:

Name of contractor
Job site/ pouring location
Date of delivery
Mix/ class of concrete
Cement type
Maximum aggregate size
Specified slump
Volume/ quantity in one cubic meter
Time of batching
Time of arrival at site
Remarks (if any excess or surplus requested RMC supply shall be
mentioned for what and where, and any other necessary information)
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 7 of 15
OPERATING PROCEDURE Revisi : 0

Start unloading
Finish unloading
Time return to plant
Other necessary information

After the completion of discharge the above delivery ticket should be prepared
by user, approved by PT. CII athourized officer and returned to PT. KDP Batch
Plant.

III. MATERIAL AND PRODUCTION CONTROL

A. Material Test

Cement

The physical and chemical analysis of cement used for the concrete will be
evaluated based on cement mill certificate provided by manufacturer or supplier
and subject to the approval of PT. KDP

Aggregate

Routine test on fine and coarse aggregate for concrete production and quality
control purpose to be carried out regularly at PT. KDP laboratory, i.e.:

Gradation test
Moisture content
Material finer than sieve no. 200
Specific gravity
Bulk density
Water absorption
 On the arrival of new material and before it is unloaded to stock pile all the
aggregate will be tested at PT. KDP laboratory in accordance with relevant
specification.

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 8 of 15
OPERATING PROCEDURE Revisi : 0

Specification

The complete test on chemical and physical properties of aggregate for the
approval of material used for the concrete will be done by the approved
independent testing laboratory and comprise :

Gradation
Water absorption
Specific gravity
Material finer than sieve no. 200
Flakiness index
Soundness test
Chloride content (Cl)
Sulphate content (SO3)
Alkaly reactivity in aggregate

Water

Since the water used for the concrete is supplied from PT. CII/ PT. PCI Jabung
Ltd main desalination plant, i..e. portable water, the test on water will be done
only for approval purpose, i.e. on :

PH value
Total dissolved solid (TDS)
Chloride content (Cl)
Sulphate content (SO3)
Suspended soil
Alkali carbonate

Admixture
 The quality of admixture will be checked regularly based on the specific gravity
of the liquid.

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 9 of 15
OPERATING PROCEDURE Revisi : 0

B. Control of Batch Plant and Mixing Equipment

All plant and equipment will be maintained in a clean and efficient working
condition,
All knife edges on weighing equipment will be kept clean all times,
All hoppers and doors will be kept clean and in efficient working order,
Any build-up in the hopper will be cleaned out daily.

The mixer at Batch Plant as well as the truck mixer will not be loaded in excess
of manufactures rated capacity.

Central and truck mixers will be maintained in efficient and clean condition with
no appreciable build-up of hardened concrete in the mixing drum, on blades or
in the loading hopper for discharge chutes.
Regular check and repairs (if necessary) will be done on mixing blades.

Calibration of Weighing Equipment

Calibration of all scales used for cement, aggregate, water and admixture
dispenser will be done before the start of concrete production subject to the
approval of PT. CII/ PT. PCI Jabung Ltd.

C. Concrete Production Control

At the start of batching the central mixer and the truck mixer will be cleaned
from any retained water inside the drum used for washing out purposes.
 All the concrete will be batched based on the batch card provided by PT. KDP
Technical Department using the mix proportions which have been approved by
PT. KDP at initial trial mixes.

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 10 of 15
OPERATING PROCEDURE Revisi : 0

All the material will be mesured within defined limits of the above batch card
and any necessary adjusment will be made to allow for variation of the moisture
in aggregate to be done by PT. KDP laboratory officer based on the approved
tables.

D. Control of Water Content, Workability and Fresh Concrete

During mixing the amount of water introduced into the mixer will be strictly
controlled and no additional water other than specified will be added to the truck
mixer before the delivery, unless specifically required and signed by PT. CII/ PT.
PCI Jabung Ltd.

After the completion of batching the mixed concrete in the truck mixer will be
inspected visually before delivery.

Sampling and testing of concrete for workability will be carried out in

accordance with ASTM C-143 and performed at the interval as per specification
Q-4 Plain and Reinforced Concrete sub para 15.3.4.4, or as per following:

No. Of cubic meters placed No. Of samples to be taken

0~50 One for each 25 Cu. meters

51~200 One for each 50 Cu. meters
201~350 One for each 75 Cu. meters
351 or over One for each 100 Cu. meters

The minimum of samples shall be three. Field test will be carried out regularly
to detect the variation of concrete density and other properties of materials.
Cylinder specimens will be made in accordance with ASTM C-39. All cylinders
shall be marked at the time of casting with the date, class of concrete and other
necessary information to identify the part of the work and from where such
 cylinders were taken and the record will be made available for further
inspection.

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 11 of 15
OPERATING PROCEDURE Revisi : 0

IV. PRODUCT QUALITY CONTROL

Stripping time, Marking and Curing of cylinder Specimens.

The cylinder specimens were made during concrete production will be stripped out from
the mould at minimum 20 hours and not more than 48 hours after the casting.

All the cylinder specimens will be identified with waterproof penmaker in accordance to
laboratory code number, date of casting and other necessary information. The record
showing class concrete, pouring location, date of cast etc. Will be available for further
inspection.

After the completion of the above process all cylinder specimens will be cured inside a
wear take in accordance with ASTM C-192 and tested at designated ages.

Concrete Control Test

All the test specimens will be made, cured and tested in accordance to specified
requirement.
Compressive strength test will be done at the designated ages which be determined byPT.
CII/ PT. PCI Jabung Ltd.

Before the test all specimens should be weighted, measured and capped by sulphur in
order to obtain the volume, density, diameter cross sectional area and plainness of the
surface to be tested.

All compressive strength test on cylinder specimens will be performed in accordance

with requirements of ASTM C-39.

Compressive strength test result to be recorded and kept available for inspection.

Certificate of compressive strength test will be provided to client after the test has been
conducted.
 Control Chart

Evaluation of compressive strength test will be done using the approved method
(ACI 214. ACI 318 and other relevant standards).

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 12 of 15
OPERATING PROCEDURE Revisi : 0

Compressive strength charts to monitor the change in target mean (average) strength,
standard deviation will be drawn on a control chart that will kept available for inspection.

Compressive strength evaluation at the early stage will be done using 7 days compressive
strength test result and to be correlated to 28 days result.

The correlation chart between 7 to 28 days will be established after sufficient data has
been available.

Statistical evaluation of cylinder compressive strength test to measure the actual average
strength, standard deviation and coefficient of variation for each class of concrete to be
done after sufficient quantity of 28 days compressive strength of each class of concrete
are available.

V. PERSONAL AND RECORD SYSTEM

In order to ensure the success in completion of the contract, PT. KDP Batching Plant
operation and concrete production will be under the supervision of experienced concrete
and material engineer and to be collaborated with an independent testing laboratory. PT.
KDP also provide experienced and well trained concrete technicians as well as truck
mixer operators and maintenance mechanics for trouble shooting and overhaul of the
equipment in order to guarantee the smooth running of concrete production.

All the record systems on material, quality control, maintenance, concrete production and
delivery to be arranged in efficient manner and easily traceable when required at all time.

Attached to this procedure is typical material and concrete production control chart and
proposed forms for quantity and quality control of ready mixed concrete.

VI. EFFECTIVE MEASURES TO BE EMPLOYED FOR REDUCING CONCRETE

TEMPERATURE (use ACI 305 Hot Weather Concreting)

Hot wether may lead to problems in mixing, placing, and curing hydraulic cement
concrete that can adversely affect the properties and serviceablity of the concrete.
 Most of these problems relate to the increased rate of cement hydration at higher
temperature and the increased evaporation rate of moisture from the freshly mixed
concrete.

PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 13 of 15
OPERATING PROCEDURE Revisi : 0

Generally, if concrete strengths are satisfactory and curing practises are sufficient to
avoid undesireable drying of surfaces, durability of hot weather concrete should not be
greatly different from similar concrete plave at normal temperature, a summing the
presence of a desirable air-void system if it is going to be exposed to cycles of freezing
and thawing.

However, the following steps will be taken in order to avoid the about problems, such as
hydration at higher temperature (concrete temperature) and evaporation rate of moisture
from the freshly mixed concrete in hot weather:

Concrete and water will be stored in a shaded area to reduce the temperature increase
due to direct sunshine.

Cement aggregate will be sprayed with water as required in order to further reduce
the aggregates temperature. (moisture cement of aggregate must be taken into
account for proper water to content ration (W/C)

As initial concrete temperature will affect the strength. The temperature of the
mixing water has the greatest effect to the concrete strength. The temperature of the
mixing water is the easiest thing to control eventhough the mixing water, used is
small compared to the other ingredients. The use of cold mixing water will be
utilized by providing Water Chiller which can decrease the water temperature up
to 12 C degree.

Concrete admixtures, such as retarded will be used as required in order to offset the
negative effect of high mixing temperature.

Batching procedures will be set up and impelemented in order to produce a uniform

quality of mixed concrete.

The dispatching of mixed concrete by trucks will be coordinated to avoid delays in

delivery i.e. minimized delivery times for concrete placement. The elapsed time of
batching to placement of concrete mixed will result in significant increeses in mixing
water demand or in slump loos.

The placement of concrete will be speeded up in order to hot weather difficulty.

 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 14 of 15
OPERATING PROCEDURE Revisi : 0

VI. DUMPING OF CONCRETE

Rejected RMC will be dumped to the disposal area designated by PT. CII/ PT. PCI
Jabung Ltd.
 PT. KARINDA DAYA PERKASA

Doc. No. : KDP-CBP-BCD-001

CONCRETE BATCHING PLANT Sheet No. : 15 of 15
OPERATING PROCEDURE Revisi : 0

LIST OF ATTACHMENT

1. Ordering flowchart

2. Concrete order form

3. Delivery ticket form

4. Daily concrete delivery control form

5. Concrete test report form

6. Manpower mobilization schedule

7. Equipment mobilization plan