A.J.P.

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

Inspection and Testing for Concrete Works

( QA/P 1331.Doc )

Oct.-2006 DATE

0 REVISION

M.D PREPARED BY 1

G.S REVIEWED BY

S.B APPROVED BY

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

1. 2. 3. 4. 5. 6. 7.

PROCEDURE NO. SCOPE AND PURPOSE APPLICABILITY RESPONSIBILITY GENERAL DEFINITIONS PROCEDURE 7.1 Receiving Inspection and Testing

7.2 In-process Inspection and testing 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 8. 9. 10. RECORDS REFERENCES ATTACHMENTS Civil and Earth Works Pre-Pour Inspection Concrete Placement Concrete Testing Form Removal Concrete Curing and Protection Finishing Grouting

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

1.

PROCEDURE NO. P1331

2.

SCOPE AND PROCEDURE The scope and purpose of this procedure is to establish a functional inspection and Testing System to ensure that the process control of concrete works is adopted and properly executed in accordance with the client/consultant specifications and applicable standards.

3.

APPLICABILITY Petroleum Product Storage Terminal at Hamriyah Free Zone.

4.

RESPONSIBILITY . Project Manager . Construction Manager . Discipline Engineer Discipline Foreman . QA/QC Supervisor . QC Inspector . Material Controller GENERAL The responsibility for the Inspection and Testing of the Concrete Work rests primarily with the Material Controller , the Discipline Engineer and the Discipline Foreman with assistance from the audit by the QA/QC Supervisor and QC Inspectors. The Discipline Engineer and the Discipline Foreman shall ensure the required work permits are available and in place on a daily basis. Similarly they shall ensure that utilized drawings are latest revisions. The Project QA/QC Supervisor shall verify compliance to this procedure by audit, and shall perform reviews on all Quality related contractual documentation. The QC Inspector shall be responsible for witnessing tests and inspections and ensure appropriate documentation. All concrete works shall comply fully with the applicable laws and Client/Consultant requirements and specifications.

5.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

6.

DEFINITIONS None

7.

PROCEDURE 7.1 Receiving Inspection All cement aggregates and water used shall be in accordance with Client / Consultant Specifications and Drawings. The material Supervisor shall control , through the proper procedure that cement, raw materials and concrete reinforcement, are in compliance. The QA/QC Supervisor shall submit to Client / consultant full details of all materials to be used for the concrete works including, if required , the names of supplies or manufactures and sources of supply , for his review and approval. The QA/QC Supervisor shall ensure that materials or sources of materials are not changed. Materials where required, shall be sampled and tested in an approved laboratory. Results of tests shall be submitted to Client / Consultant Representative. 7.2 In-process Inspection and Testing 7.2.1 Civil and Earth Works Inspection and Testing of Civil and Earth works shall be done in accordance with Procedure P1381. 7.2.2 Pre-Pour Inspection A) Forming Prior to the placement of concrete , the Discipline Engineer / QC Inspector must ensure that the forms are clean and placed in accordance with relevant drawings. B) Reinforcement The reinforcing steel must be in accordance with Project Drawings and be checked fore the following. . . . The steel is clear of the forms and soil and held firmly in place by the use of wires, chairs, spacers or concrete blocks. Mud, oil, concrete and loose scale has been removed. The steel has been installed in accordance with the foundation drawings and bending schedules as to size, location and spacing. The Spacing and radius of bends conforms to the project specifications.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

C)

Embedded Items Embedded items shall be checked as follows

The Discipline Engineer shall check the diameter, length, type, location, elevation, projection and plumbness of anchor bolts. They must be properly secured. The sleeves for anchor bolts must be checked for correct size and material, and must be centered on the bolts. Angles, inserts, plates, sleeves, block-outs and hold-downs shall be checked for size , thickness, material and location. Check for installation of conduits and ground wires, when required. Approval to Pour Concrete foundations shall not be poured until the QC Inspector or Client/Consultant Inspector has completed pre-pour inspection.

. . . D) .

7.2.3 Concrete Placement Previous to, or during the placing of the concrete, the Discipline Engineer shall check for the following: a) Concrete surfaces to receive new concrete which should have the loosened particles of aggregate and dirt or mud removed. b) The ground or existing concrete should be moistened with water. c) The minimum mixing time should be sufficient to form the uniform mass and concrete shall not exceed the time limit for remaining in the mixer. d) The slump shall be checked to avoid placing concrete too wet. Water should not be added to concrete in the field. e) Equipment made of aluminum alloy should not be used to transport or convey concrete. f) All concrete should be thoroughly consolidated by vibrating, but should not be over-vibrated. g) Vibration and compaction shall be carried out in accordance with applicable Standards. h) Concrete should not be dropped in tall forms without a drop pipe, moved with a vibrator, nor handled with any other manner, which could cause separation of materials. 5

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

i) In making large pours, an efficient system of placing concrete should be set up to keep the edges fresh or soft, in order to avoid a cold joint if there is an unexpected delay. 7.2.4 Concrete Testing Third party Technician is responsible for the testing of concrete as follows. The slump test shall be conducted by taking concrete sample from the truck spout or from the fresh concrete as it is placed in the forms. A Wellproportioned concrete mix with proper water content will gradually slump but retain its original cohesive form. A poor mix with excessive water content will slump quickly, aggregates will separate, and the specimen will disintegrate. Slump test must be conducted continually to control water content. Acceptance criteria of a slump test shall be as indicated by Client/Consultant. Specimens for each set shall be obtained at the same time and from the same batch of concrete. Form A.J.P.E.-100-008 Concrete Cylinder / Cube Test Record Summary, Shall be used for reporting on cylinder / Cube testing. A Concrete test Specimen report must be completed when specimens are taken for testing. A Standard form supplied by the testing laboratory will be acceptable. The original of this form should be forwarded to the site QA/QC office and one copy must be sent to the laboratory along with the specimen. 7.2.5 Form Removal In all cases forms shall be removed at timeframes specified in Standard. In general the following apply. Determining the time of safe removal should be based on the effect on the concrete. There must be no evidence of damage to the concrete due to stripping operation. Unless otherwise specified, the shoring under beam bottoms and supported slabs may be removed after test results indicate that the concrete has reached 2/3 of the design strength.( In special cases, such as pre-cast concrete, architectural concrete and long spans, the Client/Consultant should be consulted ) . Care must be exercised when removing forms to ensure that bolts are not disturbed and the concrete is not damaged.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

7.2.6 Concrete Curing and Protection Concrete shall in all cases be cured by employing Hessian and impervious sheeting. The concrete should be kept continuously moist or be protected by an approved curing compound. Below grade concrete shall be placed on mud mat and polyethylene sheet/ Surfaces that will be in contact with soil shall be coated with client approved waterproof material inclusive of 300mm above grade. 7.2.7 Finishing All concrete finishing will be in accordance with the approved project drawings. The finishing of concrete foundations and walls can be best accomplished immediately after the removal of forms. All concrete shall be inspected to determine that voids, form tie holes, damaged corners, etc, have been properly repaired. Finished concrete must be protected and cured as specified in the preceding paragraphs. Contraction joints in concrete slabs that require sawing will be cut within the time limit specified in the Client/Consultant specifications. Coating for underground portion of foundation shall be done in accordance with Client/Consultant Specification and Coating application shall be recorded on Form P143-2 Paint Acceptance report. 7.2.8 Grouting The Discipline Foreman shall ensure that grouting is mixed and applied in accordance with Specific Grouting Method Statement, Manufacturers recommendations and instructions. Form P133-6 Civil works Grout Release Record shall be completed. 7.3 Final Inspection and Testing The QC Inspector shall prepare, mark , store and cure test cylinders as per the client/consultant Requirements and specifications. The results of the tests shall be submitted to client/consultant in the period required in the specification. Any defective concrete work shall, at the discretion of the Client/Consultant Representative, be made good. Such rectification shall be re-tested, Inspected in accordance with original requirements. 7

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS REVISION 0 DATED OCT 2006

The QA/QC Supervisor/Inspector shall use the Concrete Cylinder/Cube Record Summary to keep records of the results of testing. The documents relevant to inspection and testing shall be kept in the QA/QC Office on site. 8. RECORDS All forms and records relevant to this procedure shall be kept in the site office by the QA/QC Supervisor and following the finish of the project repatriated to the Area Head Office to be achieved and kept for a period of Three Years. 9. REFERENCES A.J.P.E. Corporate Quality Assurance Manual. 10. ATTACHMENTS Form P133-1, Concrete Pour Inspection Form A.J.P.E 100-008, Concrete Cylinder/Cube Test Record Summary Form P133-3, Concrete Pour Release Record Form P133-6, Civil Works Grout Release Record Form P143-3, Paint Acceptance Report.