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TABLE OF CONTENTS

Pages

Issue / Revision Record 3

1.0 Scope 4

2.0 References 4

3.0 Definitions 4

4.0 Responsibility 4

5.0 Procedure 5-22

6.0 Protective Coating Application 22

7.0 Inspection and Testing 23

8.0 Supporting documents 24

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ISSUE / REVISION RECORD

Issue Revision Paragraph Description Date

1 0 All Issued for Approval 8-July-2018

NOTE: Where revisions affect the whole document, NO identification will be placed adjacent to the revised paragraph.

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1.0 SCOPE

This Quality Control Procedure defines the type and extent of inspections to be carried out to
verify that all operations involved in installation of reinforcement, placing Concrete, Curing,
finishing, Repair and coating of Structural and Non-Structural Concrete conform to specified
requirements for the Scope of work of Contract No. 103695 KAEC IV NATURAL GAS
NETWORK.

2.0 REFERENCES

SAES-Q-001 Criteria for Design and construction of Concrete structure

SAES-Q-005 Concrete foundations
09-SAMSS-97 Ready Mix Portland cement Concrete
ASTM-C 94 -09 Standard specification for ready mixed concrete
ASTM C 150 Standard specification for port land cement
ACI 318 Building Code Requirement for Structural Concrete
Contract applicable Codes, Standards, Specifications, and IFC Drawings
3.0 DEFINITIONS

ITP - Inspection & Test Plan

GAS - GAS Arabian Services
QCP Quality Control Procedure
IFC Issued for Construction
SATIP Saudi Aramco Inspection Testing Plan
SAIC Saudi Aramco inspection Check List

4.0 RESPONSIBILITY

4.1 Project Manager

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Ensures compliance by all parties to this procedure, the Quality Plan, Inspection & Test
Plan and relevant customer specifications, drawings and Industry Codes.

4.2 Construction Manager

Ensure compliance by all craftsmen to the content of this procedure, Quality Plan,
Inspection & Test Plan and customer standard requirement.

4.3 Civil Supervisor

Ensure the correct IFC drawings, approved procedures associated with the
construction of concrete structures are available to, and used by, all personnel in
charge of the work. Ensure that all submittals required by the client are duly
approved and issued for use. Confirm construction materials are available and
comply with the project specifications.

4.4 Quality Control Inspector (Civil)

Monitors daily construction activities and verifies compliance with approved

inspection and test plans. Prepares and maintains daily QC record and final
Inspection acceptance documentation where required.

4.5 Safety supervisor

Ensure work permits are obtained prior to commencement of any work. Checks
personnel and confirms compliance to safety requirements, such as wearing
personnel protective equipment. Check work areas for any unsafe conditions.
Liaise with the field supervisors ensuring that work is carried out in accordance
with project safety plan/procedures.

5.0 PROCEDURES

5.1 Concrete Reinforcement

Concrete shall be either structural or nonstructural, as follows:

a) Structural Concrete: All reinforced concrete including concrete with

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minimum reinforcement for temperature and shrinkage control. The
28 day design compressive strength (ASTM C39) shall be 28 MPa
(4000 psi) and 35 MPa (5000 psi) for water retaining structures.

b) Non-Structural Concrete: Unreinforced concrete of no significant

structural value such as lean concrete for sub-slabs. The minimum
28 day design compressive strength (ASTM C39) shall be 14 MPa
(2000 psi).

5.1.1 FBE coated / Bare reinforcing bars shall be procured and delivered to
the job site as per project specification and confirms to MTO and IFC
drawing.

Material delivered to site shall complete document and inspection, and

material testing record.

Upon material delivery to site, discipline QC Inspector shall ensure and

verify the complete record / MTC is confirmed to applicable
requirement.

FBE coated reinforcing bar shall be Protected at all times during

handling, storage, fabrication and installation.

5.1.2 The bars shall be cut exactly to the lengths indicated on the project bar
bending schedules using a bar cutter. Cutting torches shall not be
used for cutting re bars.

5.1.3 The cut ends of FBE coated rebar, shall be repaired with the approved
patching material.

5.1.4 All reinforcement shall be bent cold. Bars shall not be bent in a manner
that may damage the coating.

5.1.5
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Bars shall be bent as shown on the project bending schedules. Degree
of accuracy shall be in accordance with the project specifications.

5.1.6 A mandrel (or pin) that is fabricated from, or covered with, a collar of
wood , nylon or other non-abrasive material, which will not damage the
epoxy coating, shall be used for bending.

5.1.7 Unless otherwise specified, while selecting the size of mandrel a 1:8
(rebar : bend) diameter ration shall be used for coated rebar.

5.18 Reinforcing bars having reduced sections, kinks, and visible

transverse cracks at bends, or otherwise appear damaged in anyway,
shall not be used.

5.1.9 The rebar shall be placed and firmly tied at all intersections, except
where spacing is 300 mm or less, in each direction, which case
alternate intersections shall be tied.

5.1.10 Intersection or crossing bars shall not be welded for assembly of

reinforcement, unless otherwise permitted by the client.

5.1.11 Clearances shall be maintained from the forms by means of plastic

(PVC) chairs, spacer, and hangers spaced in accordance with project
requirements. Approved stays and block ties of size agreed by the
Customer’s representative shall be utilized.

5.1.12 ACI recommendations for minimum concrete cover shall be followed

unless specified in the project documents.

5.1.13 Epoxy or plastic-coated tie wire shall be used for FBE coated rebar,
and galvanized tie-wire for non-FBE coated rebar, to fasten reinforcing
bars by double wrapping with at least two full twists, unless otherwise
specified.

5.1.14 The cut ends of the tie wire shall be turned to the inside of the exposed
concrete surfaces.

5.1.15 Reinforcement shall be moved to avoid interference with other

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reinforcing steel, conduits, block-outs and other embedded items. If
the rebar’s are moved by more than one bar diameter or if it exceeds
the specified tolerances, the resulting arrangement shall be confirmed
with the Client.

5.1.16 Splicing of reinforcing bars shall be in accordance with the project

drawings and specifications.

5.1.17 Welded wire fabric (WWF) per ASTM A185-90A (non-FBE coated)
shall be used for slabs on grade unless otherwise indicated in the
drawings. Lapping of WWF must be equal to the spacing of cross wire
plus 50 mm. tying shall be as project requirements.

5.1.18 Finished installed rebar shall be free from oil, grease, mud, dust and
deleterious materials that may affect rebar and concrete bond.

5.1.19 Finished reinforcement shall be inspected in accordance with Saudi

Aramco Inspection Checklist (SAIC-Q-1013) for Cast-in-place
Concrete Structures and (SAIC-Q-1022) for Pre-cast Concrete
Structures.
5.1.20
Embedded items

All sleeves, inserts, anchor bolts, water stops and other embedded
items shall be installed in accordance with the design drawings and
supported against displacement.
The design of anchor bolts shall be in accordance to SAES-Q-005 and
the materials shall be in accordance to 12-SAMSS-007.
Projecting steel items (such as grating angles, slide plates, unistrut,
steel plates, etc.) which are attached to the formwork and cast at the
concrete surface shall be hot dip galvanized in accordance with ASTM
A123 or coated with the zinc rich epoxy primer in APCS-1C of SAES-
H-101. Additionally, the steel attachment, which anchors these items
to the concrete, shall be similarly galvanized or coated.
Reinforcing steel bars, anchor bolts or other steel embedments shall
not be used as the means for grounding electrical equipment and shall
not be tied to grounding neutral conductors, or any part of the lightning
protection system. Conduits, pipes and other items made from
aluminum shall not be embedded in structural concrete unless
effectively coated to prevent aluminum-concrete reaction.

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A) Type, size, detail and location of embedment not shown on the 
construction documents shall be submitted for review by license design 
professional. – ACI 318 Para. 26.8.2a 

B) Aluminum embedment’s shall be coated or covered to prevent aluminum 
concrete reaction or electrolytic action between Aluminum and Steel. – ACI 
318 Para. 26.8.2b 

C) Pipes and Fittings not shown in the construction documents shall be design 
to resist effect of Materials, Pressure, and Temperature to which they will 
subjected. – ACI 318 Para. 26.8.2c  

D) No liquid, gas, or vapor, except water not exceeding 32oC or 0.35 MPa

pressure, shall be placed in the pipes, until the concrete has attained
its specified strength. –ACI 318 Para. 26.8.2d 

E) Conduit and piping shall be fabricated and installed so that cutting,

bending or displacement of reinforcement from its specified location is
not required. – ACI 318 Para. 26.8.2f 

5.1.21 Pumped Concrete

Placing concrete by pumping methods shall also conform to the requirements

of ACI 304.2R.Slump and cylinder test samples shall be taken from the end of
the mixture truck
chute or at the discharge point of the concrete placement hose when concrete
pumps are used

Handling of Fusion Bonded Epoxy Coated Reinforcing Bars

5.2

5.2.1 Handling

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Equipment used for handling coated rebars shall have padded contact
areas. Rebar bundles shall be lifted only with a strong back spreader
bars, multiple supports, or a platform bridge to prevent bar-to-bar
abrasion from sags in the bundle of coated bars. Bars shall not be
dropped on dragged.

5.2.2 Storage

Bars shall be off-loaded as close as possible to the point of placement,

in-order to minimize re-handling. Bars shall be stored off the ground on
protective cribbing, and timbers shall be placed between bundles when
stacking, sufficiently to prevent sags in bundles. Coated and un-coated
bars shall be stored separately. The bars shall be protected from
sunlight, salt spray and weather exposure using opaque polyethylene
sheeting. For stacked bundles the protective covering should be draped
around the perimeter of the stack and secured adequately. Free air
circulation around bars should be ensured to prevent condensation
under covering. Walking on coated steel reinforcing bar should be
minimized.

5.2.3 Coating Damage & Repair

Minor coating damages may be repaired with a two-part epoxy patching

material, or alternative as recommended by the manufacturer. Prior to
patching, rust shall be removed from the area and repair carried out
according to the manufacturers recommendations. Rejected bars shall
quarantine.

When placing re-bars, all wire bar supports, spacers and tying wire
should be coated with dielectric material.

5.3 Formworks

5.3.1 Inspection and testing of the prepared sub-grade shall have been
conducted satisfactory, prior to the construction of formworks.

5.3.2 Forms shall be fabricated with sufficient lateral and diagonal bracing,
in a way, which will resist all loads and displacement.

5.3.3 Forms shall withstand vibration and other loads occurring during the
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construction operation.

5.3.4 Conduits, pipes and spacers between forms, rebar and other
embedment shall be properly installed and inspected before closing
forms.

5.3.5 Forms intended for elevated slabs, beams, canopies and the like
should be adequately shored. Metal frames used for shoring shall not
be loaded beyond the safe working load recommended by the
manufacturer.

5.3.6 Install forms for columns with sufficient ties and braces to prevent any
lateral movement and check for plumpness.

5.3.7 Sufficient braces, spacers and tie rods shall be used for wall
formworks to ensure that the forms and re-bar is not displaced during
concrete pouring.

5.3.8 Continuous tie rods with PVC sleeve, PVC cones and wing nuts, or
other approved supports shall be used for tightening and aligning.

5.3.9 For watertight wall enclosures, i.e. sumps and tanks, tie rods with
coupling nuts that will be installed along the center of forms with wing
nuts, or other approved supports suitable for water retaining
structures, may be used.

5.3.10 For walls requiring monolithic construction, i.e. vertical cylindrical

concrete tanks and chimneys, vertical slip forms or other approved
formwork supports may be used.

5.3.11 Scaffolding or work platforms completely encircling the area of

placement shall be used to ensure safe access to all areas.

5.3.12 Coordinates of centerlines, gridlines, plumb, slopes and control joints

shall be checked against IFC drawings, and installation tolerance
shall not exceed the limit of the project specifications.
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5.3.13 Forms should be mortar tight and paste tight for all concrete
construction to avoid loss of mortar or leakage that will cause voids in
the concrete surface. Defective forms will not be used.

5.3.14 Forms shall be thoroughly cleaned of all dirt mortar and foreign matter
and coated with appropriate oil (release agent) in accordance with the
manufacturer’s recommendation, prior to form installation. Form
release agents shall not be applied where concrete surfaces will
receive special finishes.

5.3.15 Bolts, anchors, dowels, fastenings or any other items to be embedded

in concrete shall be accurately positioned and secured to avoid
displacement. Wooden templates must be accurately and carefully
set for anchor bolts and other such items.
 All sleeves, Inserts anchor bolts, water stop and other embedded
items shall be installed in accordance with the design drawings
and supported against displacement.
 The design anchor bolts shall be in accordance to SAES-Q-005
and the material shall be in accordance to 12-SAMSS-007.
 Projecting steel items (such as grating angles, slides plates,
unistrut, steel plates etc) which are attached to the form work and
cast at the concrete surface shall be hot dip galvanized in
accordance with ASTM-A123 or coated with the zinc rich epoxy
primer in APCS-1C of SAES-H-101 Additionally the steel
attachment, which anchor these items to the concrete shall be
similarly galvanized or coated.

 Reinforcing steel bars, anchor bolt or other steel embedments

shall not be use as the means for grouting electrical equipments
and shall not be tied to the grounding neutral conductors or any
part of the lightening protection system.
 Conduits, pipes and other items made from aluminum shall not be
embedded in structural concrete unless effectively, coated to
prevent aluminum concrete reaction.
 Minimum clear distance from anchor bolts or anchor bolt sleeves
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to edge of concrete shall be 100mm. Metallic sleeves are not
allowed and anchor bolts shall not be in contact with reinforcing
steel.

5.3.16 Miscellaneous items that are deemed necessary for installation of

formworks such as chamfer strips to exposed corners, construction
joints, key ways, expansion joints, water stops and spacers, shall be
installed.

5.3.17 All sawdust, chips, construction debris and other extraneous materials
shall be removed prior to inspection.

5.3.18 The formworks shall be provided with adequate safe access for
workers and inspectors. Platforms and walkways shall be provided
with handrails when deemed necessary. Temporary openings shall be
provided, where interior area of formwork is inaccessible for clean out
and for inspection before concrete placement.

5.3.19 Foundation numbers will be marked on the formwork and the tag
numbers removed from the reinforcement.

5.3.20 Finished formworks shall be inspected prior to closing, to verify

conformance with drawings.

5.4 Concrete Pouring

5.4.1 Confirmation is required that the correct concrete mix and quantities
have been requested for the planned pours.

5.4.2 When the placement consists of several layers, concrete delivery

should be schedule so that each layer is placed while preceding one is
still plastic, and vibration shall be done through preceding layers.

5.4.3 When pouring is scheduled early morning hours or dusk, adequate

lighting shall be provided for construction and inspection activities.

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Sampling, testing, evaluation and acceptance of concrete shall be in
accordance with the Project Specifications, Saudi Aramco Standard
and Inspection test plans.

5.4.4 All forms and rebar shall be adequately cleaned before concrete is
poured.

5.4.5 Ready mix concrete delivered in trucks not having operable revolution
counters shall not be permitted.

5.4.6 Concrete shall be discharged from the mixer within 90 minutes or 300
revolutions of the mixer from the time the mixing water was added.
ASTM C-94, Sec. 11.7.

5.4.7 Concrete delivered at a temperature in excess of 32°C or that fails to

maintain a temperature of 32°C until used, shall not be permitted.

5.4.8 No aluminum parts shall be placed in contact with concrete

5.4.9 Equipment made of aluminum alloys shall not be used for pump lines,
chutes used to discharge concrete from a truck mixer.

5.4.10 Raking shall not be used for movement of concrete after placement.

5.4.11 Placing concrete by dropping from a height greater than one meter is
not acceptable, unless it will be deposited by chutes or other approved
methods." (By any means or methods that concrete is not permitted to
be dropped freely more than 1meter).

5.4.12 Concrete shall be placed as near as practical to its final position to

avoid segregation due to re-handling or flowing.

5.4.13 Concrete that has partially hardened or has been contaminated by

foreign materials is not to be placed in the structure.

5.4.14 Concrete shall not be re-tempered.

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5.4.15 Concrete shall be placed on a clean surface free of standing water.

5.4.16 Poured concrete shall be vibrated and trowelled as necessary to

achieve homogeneous placement and smooth finish. The vibrator shall
be thoroughly worked around reinforcement, embedded fixtures and
into corners of form in order to achieved consolidation. Vibrator
insertion should be properly spaced and overlapped and should not
penetrate into the previous layer. The vibrator shall always be
removed slowly.

5.4.17 When Immersion type vibrators are used to consolidate concrete

around epoxy coated reinforcing bars, the vibrators should be
equipped with rubber or non-metallic vibrator heads.
(ASTM A775/A775M, Sec. XI3.15)

5.4.18 Concrete will be deposited in layers as level as possible so that

vibrator does not need to move the concrete laterally.

5.4.19 Where placement of concrete consists of layers, each layer should be

discontinued and the concrete should be allowed to harden.

5.4.20 Should the concrete approach time of setting, vibration should be

discontinued and the concrete should be allowed to harden.

5.4.21 Once pouring is complete, disturbance of the newly poured concrete

should be avoided to prevent any possibility of cracks or impairment of
the structure.

5.4.22 Concrete is to be covered by protective spraying or plastic sheeting or

wet hessian, immediately following completion of pouring, according to
the project requirements, to prevent premature drying, excessive
hot/cold temperature and mechanical disturbances.

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5.4.23 If the concrete placement is stopped for longer than the initial setting
time, the joint should be treated as a construction joint. Construction
joints not shown on approved for construction drawings shall only be
placed with prior approval of the client.

5.4.24 Construction Joints

A notification will be issued to client for inspection of preparatory work

prior to concrete placement.

The hardened concrete shall be clean and free of laitance.

Cleaning by wire brushing can be done when the concrete is still soft
enough that laitance can be removed, but hard enough to prevent
aggregate from loosening. If only a few hours elapsed between
successive placement a visual check shall be carried out to ensure
that no loose particles, dirt, and laitance remain.

The pre pared surface should be moistened thoroughly before

placement of fresh concrete.

Concrete that has set should be cut chipped, or sandblasted to present

a clean, rough surface for the new concrete in the next fill.

Concrete that has been placed recently does not require additional
water but concrete that has dried out may require saturation for a day
or more. The surface should be just damp at the time of placement.

Apply an approved grout or concrete bonding agent on the prepared

surface before the successive layer of concrete is placed.

The new concrete shall be vibrated thoroughly in order to be

adequately bonded to the hardened concrete.
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A) Standing water shall be removed from place of deposit before concrete is 
placed unless a tremie is to be used or unless otherwise permitted by both 
the licensed design professional and the building official. – ACI318 Para. 
26.5.2.1b 

B) Masonry filler units that will be in contact with concrete shall be 
prewetted prior to placing concrete. – ACI 318 Para. 26.5.2.1c 

C) Concrete shall be supplied without interruptions sufficient to permit  loss 
of workability between successive placements that would result in cold joints. 
–ACI 318 Para. 26.5.2f4 

5.5 Dismantling of Formworks

5.5.1 Forms and shoring may be removed when the concrete has already
attained its strength to support its own weight and imposed construction
loads.

5.5.2 Forms for columns, walls, side beams and other parts not supporting
the weight of concrete shall be removed as soon as the concrete has
sufficiently hardened to prevent damage to the concrete surface during
stripping operation. A 48 hours curing period would be sufficient after
casting except with forms that provide structural support. Where
expeditious removal is necessary the civil supervisor shall plan and
direct the staged removal.

5.5.3 Forms for beam soffits supporting slabs or other parts that support the
weight of the concrete shall not be removed until concrete has attained
its designed strength. Re-shoring will be provided when necessary to
safely support the structure after stripping the forms. No superimposed
load shall be applied to self-supporting members before the 28-days
strength has been verified by field-cured cylinders.

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5.5.4 Form and shoring materials shall be cleaned and stockpiled promptly
after stripping. Re-use of forms that do not show any defects, is
acceptable.

5.6 Concrete Curing

5.6.1 Curing of concrete elements shall be monitored and controlled in

accordance with the project specifications.

5.6.2 As soon as concrete has taken its initial set (or in any case not more
than 12 hours after completion of casting) protective plastic cover
sheeting shall be removed and curing shall proceed in the following
manner.

5.6.2.1 Wet thoroughly the concrete and overlay with saturated

hessian.

5.6.2.2 Cover with protective plastic sheeting which is free of holes

and tears. Secure properly at joints and ends to prevent
ingress of wind causing fast evaporation of water.

5.6.2.3 Continuously wet the hessian throughout the curing period.

5.6.2.4 For high-early strength concrete, maintain in moist condition

generally for a period of at least 7 days following placement
of concrete.

5.6.3 For concrete other than high early strength, maintain in moist condition
generally for a period of at least 7 days following placement of
concrete.

5.6.4 Curing water shall be cool and dissolved solids shall not exceed the
specification limits.

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5.6.5 Liquid membrane forming curing compound may be used where

permitted. Liquid membrane curing compounds shall not be used on
surfaces to receive bonded treatments, tiles, paint or additional
concrete. Regular inspections shall be maintained during the curing
period for Cast-in-place Concrete Structures (SAIC-Q-1015) and Pre-
cast concrete Structures (SAIC-Q-1028).

5.6.6 Concrete curing as per SAES-Q-001 Sec 10

 Structural concrete shall be continuously water cured in accordance with

recommendations of ACI 305R, ACI 308 and as modified below.
 Maximum total dissolved solids in water used for curing shall not exceed
1000 parts per million.
 Water curing shall be continuous until the compressive strength has
reached 70% of the specified strength, but not less than what is specified in
Table 5.1.
 The saturated burlaps shall be covered with a plasticized sheet vapor
barrier, minimum 0.15 mm (6 mils) in thickness and shall be kept in contact
with the concrete surface at all times.
 Curing Compound shall be in accordance with ASTM C309 or equivalent
and verified by independent lab on monthly basis.

5.7 Concrete Repair

5.7.1 Surface repairs – Lean grout mix method

Concrete repair shall be as per SAER-5803 concrete repair.

5.7.1.1 Surface defects shall be repaired as soon as practicable after

form removal at such time in such manner that shall not
delay, interfere with, or impair the proper curing of fresh
concrete.

5.7.1.2 Repair areas such as projections, depressions, roughness,

honeycombs, and air holes shall be indentified and marked

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for repair. Form ties or bar supports visible at the surface
shall be cut back 25 mm minimum.

5.7.1.3 Extreme care shall be exercised to avoid damage to the rebar

or coating during preparation of the repair.

5.7.1.4 If any rebars are exposed, touch up will be done as required,

with a suitable patching compound.

5.7.1.5 Surfaces of concrete will be roughened using a chipping

hammer, and cleaned by air/water blasting or by brushing
with a stiff brush and allowed to dry.

5.7.1.6 The surface will be prepared as required, by applying a

suitable bonding agent and allow becoming tacking.

5.7.1.7 Using the same approved sand used in concrete, prepare a

stiff cement/sand mix in the proportions: 1:1 (or leaner)
gauged with 1 part bonding agent to 3 parts clean water.
Alternatively as approved prepackaged grouts and patching
compounds may also be used. The color shall match the
surrounding area.

5.7.1.8 The resulting mixture will be placed on the prepared surface,

compacted firmly and leveled out with minimum trowelling.

5.7.1.9 The surface may be lightly damped or protected by covering

with damp sacking or polyethylene sheeting for 24 hours.

5.7.2 Repair of cracks – epoxy injection method

5.7.2.1 Epoxy injection shall only be used if further cracking is not

anticipated.

5.7.2.2 Prepare a groove at the surface ranging in depth; typically,

from 6 to 25 mm. Clean the groove by flushing with water
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and dry. Epoxy sealant is placed into the dry groove and
allowed to cure.

5.7.2.3 Routing and sealing is also used to treat both fine pattern
cracks and larger, isolated cracks for waterproofing by
sealing cracks on the concrete surface where water stands,
or where hydrostatic pressure is applied.

5.7.2.4 Follow the course of crack and mark out the location for
epoxy injection nipples.

5.7.2.5 Pre-drill holes below the apex. of the V-grooved section and:
glue the nipples with epoxy or cement based mortar. A
vacuum chuck and bit, or a water-cooled core bit, is useful in
preventing the cracks from being plugged with drilling dust.

5.7.2.6 Mix the epoxy according to manufactures instruction with the

use of mechanical stirrer, like a paint-mixing paddle.

5.7.2.7 If the crack is vertical or inclined, start to inject the epoxy in

the lowest nipple at a pressure lower than 10 bars. When
epoxy comes out from the nipple above, discontinue
injection and the lower nipple is then capped. Transfer
injection to the forth nipple and the process is repeated until
the crack has been completely filled and all nipples have
been capped.

5.7.2.8 For horizontal cracks, the injection should proceed from one
end of the crack to the other in the same manner.

5.7.2.9 The crack is full if the pressure can be maintained. If the

pressure cannot be maintained, the epoxy is still flowing into
unfilled portions or leaking out of the crack.

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5.7.2.1 After the injected epoxy has cured, the surface seal should
be removed by grinding or other means as appropriate.

5.8 Pre casting

5.8.1 This shall include complete transportable foundation. Fabrication will

be under the supervision of a yard supervisor and several different
specialist crews, all under the supervision of foremen. QA/QC
department shall monitor and check all fabrication work at fabrication
yard.

5.8.2 Project construction department will assess the prefabrication

requirements and schedule of the works to be performed and the order
of the works. Project construction department will consider the
availability of materials and issue necessary change request to project
procurement, if required.

5.8.3 The yard supervisor will assign tasks to the appropriate section and
ensure that there is sufficient manpower available to perform the works
in a timely manner.

5.8.4 When sufficient forms have been prepared to perform a batch concrete
pour, a time shall be scheduled. Notification for the inspection of
formwork, reinforcement, anchor bolts and embedded items shall be
issued prior concrete pouring (SAIC-Q-1021 & SAIC-Q-1023).

5.8.5 Concrete shall be ordered from approved source. QC department shall

check the strength value of the order prior to release of the order.
Notification shall be issued for the pour and testing services (SAIC-
Q1025).

5.8.6 On conclusion of satisfactory batch testing the foundation shall be

poured. This operation shall be a “witness” point for which the usual
notice will be given to client. However, in the event that the Client does
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not attend, concrete pouring will still take place as scheduled, with QC
Inspectors attendance subject to acceptance of the batch. The
foundation number shall be marked on the concrete prior to removal of
the formwork.

5.8.7 Cured pre-cast elements, after attaining the specified design strength
shall be inspected and moved to the designated storage areas where
they shall be protected from any mechanical injury.

5.8.8 Elements of pre-cast foundations, which are to be in direct contact with

the ground, shall be painted in accordance with project specifications
and relevant work instructions.

5.8.9 QC department shall monitor the cylinder testing which shall be

performed by an approved 3rd party agency. On achieving design
strength the foundation shall be released to site for construction.

5.8.10 The pre-cast foundations shall be transported to site and placed in

position on the prepared pad. Any coating damage shall be repaired
using a suitable coal tar epoxy or bituminous paint and prepared for
backfilling.

5.9 In-situ Casting

5.9.1 In situ casting shall be used for preparation of large foundations or for
foundations where safe access cannot be achieved with pre-cast units.

5.9.2 Pre-formed reinforcement and embedment may be delivered to site and

placed in position, or may be fabricated in-situ.

5.9.3 Prior to construction of the formwork, the blinding concrete pad or other
prepared area, shall be cleaned of all loose or foreign materials using
blower or hand broom. Casting, which is to be placed direct to ground
and where blinding concrete is not shown on the drawings, will require
the placement of a layer of polyethylene sheeting under reinforcement.
(SAIC-Q-1012 & SAIC-Q-1013).
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5.9.4 Formwork shall be set around reinforcement, ensuring spacers and tie
rods to maintain position during pouring operation.

5.9.5 Access scaffolding shall be erected for pouring operation, if required.

5.9.6 The blinding concrete surface shall be clean & wetted with water prior
to concrete placement, to prevent absorption of water from the
concrete.

5.9.7 Pre-inspection notification and pouring time shall be given to the client
and third party laboratory (SAIC-Q-1060). Order concrete and pump.
5.9.8
Placing Concrete
 Concrete shall be placed in accordance with ACI 301 - 05,
Chapter 8, ACI 304R and this standard.
 For Hot Weather Concreting requirements, When hot
weather conditions exist, contractor shall place concrete in
compliance with ACI 305R and ACI 301 - 05.
 Equipment made of aluminum alloys shall not be used for
pump lines, tremies, or chutes used to discharge concrete
from a truck mixer.
 Concrete shall not be placed prior to a recorded pre-
placement inspection and authorization to proceed by Saudi
Aramco.
 Raking shall not be used for movement of concrete after
placement.
 Vibrators shall not be used to move concrete inside forms.
 Retempering of concrete after placement is prohibited.
 Concrete shall not be dropped freely where reinforcing will
cause segregation nor shall it be dropped freely more than 1
m.
 Concrete shall be deposited as near as possible in its final
position to avoid segregation due to re-handling or flowing.
 Placed concrete shall be consolidated by mechanical
vibrating equipment supplemented by hand spading, rodding
or tamping. Equipment and procedure for consolidation of
concrete shall be in accordance with ACI 309R.

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 Concrete shall be placed on a clean surface. Standing water
shall be removed prior to placement of concrete.
 The use of precast concrete or mortar blocks as bar supports
and spacers discussed in ACI 301 - 05, shall be prohibited.
However, the use of PVC Schedule 80 pipe as spacer is
allowed. The PVC pipe shall be notched at the bottom to
allow the ingress of concrete. Typical samples shall be
submitted for Supervisor of Civil Engineering Unit/CSD for
approval.

5.10 Grouting

5.10.1 Grouting work shall commence in accordance project Specification

and applicable standard requirements in conjunction with GAS QCP-
CIV-005 Grouting work.
Selection of appropriate grout for the given structure shall be in
accordance with the project specifications.

5.10.2 Base plates and concrete surfaces must be free from oil, grease and
other deleterious materials.

5.10.3 Concrete with laitance must be cut back to a sound base.

5.10.4 Concrete surfaces must be roughened. All debris shall be removed by

pressurized air.

5.10.5 A leak proof formwork shall be constructed using foam rubber strip or
mastic sealant beneath the constructed formwork and between joints.
Include outlets for the pre-soaking water.

5.10.6 A bond breaker consistent with manufacturer’s recommendations may

be applied to the surface of the formwork in contact with the grout.

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5.10.7 The area for grouting shall be flooded with clean water and allowed to
soak for several hours. The surface of the concrete shall be damp but
fee from standing water.

5.10.8 Grout mixing and placing shall be as per manufactures instruction /

recommendation. All grout shall be placed in only one direction to
prevent trapping air.

5.10.9 The grout shall be cut back at a 45˚ to the lower edge of the base
plate after it has reached its initial set unless otherwise specified.

5.10.10 After completion of grouting all exposed areas shall be cured with
water for at least 7 days.

5.10.11 Grout cubes shall be prepared for compressive strength test.

Application of Protective Coatings to Concrete Structures.

Coating and Protection as per SAES-Q-001 Sec.11
A plasticized sheet vapor barrier, minimum 0.15 mm (6 mils) in thickness,
shall be placed beneath slabs on grade. Outdoor sidewalks are
exempted from this requirement.
A plasticized sheet vapor barrier, minimum 0.15 mm (6 mils) in thickness
or a 50 mm sub-slab (lean concrete) shall be placed beneath concrete
foundations.
A plasticized sheet vapor barrier shall be placed below and around the
sides of concrete that is placed directly into excavation without the use
of formwork, where coal tar or bitumen coating cannot be applied
All concrete surfaces in direct contact with earth shall be coated with two
coats of coal tar or bitumen coating that conforms to APCS-3 or APCS-
10 of SAES-H-101. The coating shall be compatible with the curing
compounds.
Where concrete surface protection is required it shall be in accordance
with ACI 515.1R.

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7. Inspection and Testing:

7.1 Pre-Pour Inspection

7.1.1 Construction and erection of formwork shall comply with the requirements
contained in IFC drawing and as per standard requirements Section 9 of SAES-Q-001
Construction of Concrete Structures.

7.1.2 Fixing of miscellaneous items, embedment’s and anchor bolts shall comply
with SAES-Q-001 Construction of Concrete Structures.

7.1.3 Wall or Column forms shall not be closed until the QC Inspector and other
Parties specified in the related ITPs have inspected the steel reinforcement and all
embedded items.

7.2 Inspection of Concrete Receival and Field Testing:

7.2.1 The field tests for slump, concrete temperature and ambient temperature tests
shall be performed by the Qualified Lab Technician on site to the specified testing
standards and the results recorded.

7.2.2 If any field test indicates that the concrete is deficient, the Field Technician shall
immediately notify the QC Inspector, who shall reject the concrete truckload in
question.

7.2.3 Appropriate tests of fresh concrete, on delivery to the placement site, shall be
performedin accordance with 09-SAMSS-97 Ready Mix Portland Cement Concrete.

7.2.3 The QC Inspector shall perform surveillance inspection to ensure proper cleaning
prior to placement i.e. tie wires, nails, bits of wood and cleaning of windblown sand is
removed.

7.2.4 All inspections shall perform as per inspection testing Plan, Notification shall be
issued to client as per contract / and standard requirement.

7.2.5 Joints shall as per SAES-Q-001

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Joints not specified on the design drawings, shall be in accordance with ACI 301
05,Chapter 2Paving or slab construction joints not specified on the drawings shall
be located at column centerlines and intermediate intervals. Waterstops shall be
provided in joints where watertight construction is required in accordance with ACI
504R. Waterstop type shall be specified and shown on the drawings and shall
satisfy the function and operation of the structure

ACI 504R, “Guide to Joint Sealants for Concrete Structures,” shall be used to
prepare and select proper material for all installations.
Joint filler strips for expansion joints shall conform to ASTM D1751 or ASTM D1752.
Type shall be as noted on the design drawings.
Joints sealer shall conform to 09-SAMSS-075.

7.2.6 Testing and inspection

The contractor shall employ an independent Saudi Aramco approved testing agency
to perform field and laboratory testing which shall include compressive tests of
molded concrete cylinders, test for slump, unit weight, air content (where air-
entrainment is required) and fresh concrete temperature. All testing shall be in
accordance with 09-SAMSS-097, “Ready-Mix Portland Cement Concrete.”
Contractor shall submit 28 days concrete compressive strength test report to verify
& ensure the foundation & other structure that it meets the requirement of project
specification as per SAES-Q-001

8.0 SUPPORTING DOCUMENTS

RECORDS FORM No. FILE LOCATION REMARKS

Supporting documents shall be in accordance with the project requirements as specified in

PQP, SATIP, SAIC’s.

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