Concrete Handbook - 1

FOR SHIMIZU INTERNAL USE ONLY.
ANY UNCONTROLLED COPYING, DISTRIBUTING

AND REPRODUCING ARE STRICTLY PROHIBITED.
SC JKT
CONCRETE HANDBOOK
FIRST EDITION, APRIL 2016
FOREWORD
Delivers Good Concrete Quality through a Deep Understanding
Concrete is a friend of the environment in all stages of its life span, from
raw material production to demolition, making it a natural choice for
sustainable construction. However, SC JKT’s projects seem to have serious
problems in concrete works, especially slab shrinkage cracks.
SC JKT Concrete Committee was established in purpose to overcome
serious concrete problems happened in SC Jakarta projects. This handbook is
a compilation of our studies, discussions, and investigations to be used for
guidance and reference for all engineers to deepen the understanding about
concrete starts from raw material characteristic, mixing design, to concrete
production process in batching plant, until concrete casting and maintenance
during construction.
We understand that quality is never an accident; it is always the result
of high intention, sincere effort, intelligent direction, and skillful execution.
Through the provision of this book, we hope we all can improve our skills and
knowledge to deliver high quality of concrete.
Concrete Committee
Shimizu Corp. Jakarta Office
April 2016
i
ACKNOWLEDGEMENT
SC JKT concrete handbook was developed with inputs from concrete suppliers, concrete
consultant, Shimizu Institute of Technology (as a part of Shimizu R&D division) and members
from the various positions in Shimizu Jakarta Office.
We would like to thank the following institutions for sharing their good practice and
knowledge with us and willing to be our pilot projects for:
SHIMIZU CORPORATION INSTITUTE OF TECHNOLOGY
ADMATERIALS TECHNOLOGIES PTE LTD
PT. ADHIMIX PRECAST INDONESIA
PT. PIONIRBETON INDUSTI
PT. SCG READYMIX INDONESIA
PT. KARYA BETON SUDIRA
In the first edition of this handbook, a technical concrete committee was formed to endorse
the bottom line requirements. We wish to gain express our gratitude to the members of their
contributions.
SC JKT Concrete Committee
Management Representative : Tetsuo Yamamura Regional Deputy Director
Tetsuo Oishi General Manager (GM)
Makoto Fujii Deputy GM
Dodi Pratondo Deputy GM
Advisors : Masato Tsujino Dr. Eng. Concrete Researchers (SIT)
Hideo Fujiwara Senior QAQC Advisor
Manabu Yamada Deputy GM, Structural Design Dept.
Coordinator : Dian Pramitarini K. QAQC Engineer
Members : Chin Fong Lock Procurement
M. Sulaiman Procurement
Karina Shaska QAQC Engineer
1
M. Fariza Rachman QAQC Engineer
Nachi Hiroyuki Planning Manager, MNC Project
Sridhar D.V. Ass. Planning Manager, MNC Project
Yoga Makutaraditya QAQC Engineer, MNC Project
Nurul Hidayat Alam QAQC Manager, SIMA Project
Prayoga QAQC Engineer, SIMA Project
Raju Kumar M. QA Manager, MRT CP 104-105
Nishizawa Naoto QAQC Engineer, ASTRA Project
Cherniko Zubaidi QAQC Engineer, ASTRA Project
Rino Bagas Nugroho Site Engineer, TOTO Project
Efendi Yasin Site Engineer, B|BRAUN Project
Dian Pramitarini K.
QC Section
Shimizu Corp. Jakarta Office
April 2016
2
CONTENT
FOREWORD.................................................................................................................................................................. i
ACKNOWLEDGEMENT ................................................................................................................................................ 1
CONTENT .................................................................................................................................................................... 3
1 CONCRETE CONTROL & REQUIREMENT FOR SHIMIZU JAKARTA OFFICE ........................................................... 5
1.1 ORGANIZATION .......................................................................................................................................... 7
1.2 FLOW CHART .............................................................................................................................................. 7
1.3 REQUIREMENTS ........................................................................................................................................ 10
1.4 ACTIONS TOWARDS INSUFFICIENCY......................................................................................................... 11
2 CONCRETE RAW MATERIALS ............................................................................................................................ 14
2.1 BOTTOM LINE REQUIREMENTS ................................................................................................................ 15
2.2 MATERIAL SOURCES ................................................................................................................................. 17
3 CONCRETE PRODUCTION CONTROL ................................................................................................................. 31
3.1 BOTTOM LINE REQUIREMENT OF BATCHING PLANT FACILITIES.............................................................. 32
3.2 BOTTOM LINE REQUIREMENT OF BATCHING PLANT PROCESS................................................................ 36
3.3 BATCHING PLANT REFERENCES ................................................................................................................ 38
4 CONCRETE DESIGN ........................................................................................................................................... 63
4.1 BOTTOM LINE REQUIREMENT .................................................................................................................. 64
4.2 BASIC OF MIX DESIGN............................................................................................................................... 64
4.3 PREVIOUS PROJECT REFERENCES ............................................................................................................. 69
5 CONCRETE CONTROL FOR SITE CASTING.......................................................................................................... 77
5.1 BOTTOM LINE REQUIREMENT OF CONCRETE SITE CONTROL & MONITORING ....................................... 78
5.2 SC JKT CONSTRUCTION & QUALITY CONTROL SHEET............................................................................... 80
5.3 JOB DESCRIPTION SUMMARY OF CONCRETE PIC ..................................................................................... 89
6 DEFECT IN PREVIOUS PROJECTS & PREVENTIVE MEASURES............................................................................ 95
6.1 SLAB CRACKS ............................................................................................................................................ 96
6.2 LONG SETTING ........................................................................................................................................ 107
6.3 CONCRETE HONEYCOMB ........................................................................................................................ 111
6.4 CYLINDER TEST FAILURE ......................................................................................................................... 117
7 SHIMIZU CONCRETE INVESTIGATION RECORD ............................................................................................... 122
7.1 KAO KKD Project ..................................................................................................................................... 123
7.2 JFE Project............................................................................................................................................... 125
7.3 MNC & ASTRA Tower Project ................................................................................................................. 125
7.4 Sami JF Project ........................................................................................................................................ 136
7.5 SC JKT Concrete Committee ................................................................................................................... 138
3
8 QUALITY CHECK SHEET ................................................................................................................................... 141
8.1 BATCHING PLANT INSPECTION CHECK SHEET ........................................................................................ 142
8.2 SITE INSPECTION AND MONITORING SHEET .......................................................................................... 161
9 AUDIO VISUAL REFERENCES ........................................................................................................................... 172
LIST OF REFERENCE................................................................................................................................................. 174
APPENDIX ............................................................................................................................................................... 177
4
1 CONCRETE CONTROL & REQUIREMENT
FOR SHIMIZU JAKARTA OFFICE
5
[QC-Concrete-STD-RQ00 CONCRETE CONTROL & REQUIREMENTS]
CONCRETE CONTROL &
REQUIREMENTS FOR SHIMIZU JAKARTA OFFICE
_____________________________________________________________
SC JKT CONCRETE COMMITTEE 2016
6
1.1 ORGANIZATION
SC JKT Concrete
OFFICE Committee
Concrete Concrete
Projects PIC PIC
Concrete Readymix Readymix Readymix

Suppliers
Chart 1.1 Organization Chart of SC JKT Concrete Control System
1) SC JKT Office
Responsible to set up SC JKT concrete standard and ensure all the batching plant that
supply concrete to all Shimizu Jakarta Projects has met the requirement stated through
continuous report analysis and random inspections. Moreover SC JKT office shall also
ensure projects and batching plant, implement and execute in accordance with QC JKT
standard.
2) Project Concrete Person in Charge

Responsible to do direct batching plant control and inspection based on SC JKT standard in
timely basis and ensure quality compliance to the standard during site works. Moreover,
the project concrete person in charge also responsible to conduct material and/or concrete
tests to independent laboratory to secure quality.
3) Concrete Supplier
Responsible to follow all SC JKT concrete standards and support SC JKT project concrete
person in charge to do required tests and inspections.
1.2 FLOW CHART
1.2.1 INITIAL STAGE

a) Before Execution of Trial Mix
Project concrete person in charge shall do several check and inspection before trial mix
execution based on QC-Concrete-STD-JD01 forms as below listed:
Batching Plant Inspection
Conduct batching plant inspection to review its profile (production capacity, etc.),
facilities and raw material prior to trial mix execution. Some actual raw material
testing is required to conduct at the time of this inspection. Any discrepancy found
during this inspection shall be rectified and followed up prior to trial mix execution.
Admixture Dosage Confirmation
7
Get confirmation from admixture supplier regarding dosage use for particular setting
time. Trial mix may be required to ensure strength and setting time actual
achievement.
Mix Design Confirmation
Review on mix design composition to meet SC JKT standard especially W/C ratio,
cement and water content, S/A ratio and designated admixture and setting time.
Confirm the value of standard deviation used to design required F cr complete with
the data (which used to calculate the standard deviation). It is preferably that the
data comes from previous Shimizu project which can be assured or validated.
Structure designer’s approval is required to conduct trial mix.
b) Trial Mix Execution

During trial mixing, project concrete person in charge shall do several check and
inspection based on QC-Concrete-STD-JD01 forms as below listed:
Batching Plant Condition Check
Review on critical batching plant facilities condition such as conveyor, admixture
dispenser and material stock.
Material Testing for Water Adjustment
Conduct moisture control and water absorption test for fine aggregate to get surface
moisture percentage that will be used for water adjustment.
Batching Process Check
Review on mix design to meet the approved version. Project concrete person in
charge also required checking and review mix design adjustment based on surface
moisture content. When batching in process, it is required to check and review actual
accuracy of material mixed to meet the tolerance.
Fresh Concrete Check
It is compulsory to control slump loss and temperature in every 30 minutes until the
designated setting time to review the concrete workability. Salinity test also shall be
conducted in the time of trial mixing.
c) Trial Mix Result Review

Result of slump loss and temperature monitoring as well as concrete strength result on 7
days and 28 days shall be reviewed and approved by structure designer prior to concrete
supply. Result of 28 days test shall not be less than designated Fcr (refer to 1.2.1 part a).
8
1.2.2 CONSTRUCTION STAGE
Chart 1.2 Flow Chart of Concrete Batching Plant Selection & Trial Process
a) Concrete Checking Cycle

Project concrete person in charge are required to control and conduct testing and
inspection in every concreting cycle to confirm and monitor concrete quality based on
QC-Concrete-STD-JD02 forms as below listed:
Before Concreting
Project shall prepare concrete casting plan prior to concreting work. Project concrete
person in charge shall confirm batching plant condition, do moisture test and check
mix design adjustment done in batching plant based on free moisture content.
Concreting Time
Project concrete person in charge shall confirm concrete consistency in batching plant,
both batching record and actual fresh concrete condition through slump and
temperature check for the first 5 trucks.
On projects, delivery each truck mixer shall be monitored as well as cylinder sample
code and provision control.
After Concreting
Project shall monitor cylinder samples maintenance, curing activity, and concrete
compressive strength result. Moreover, structure clearance also shall be conducted to
check final result of concrete.
b) Routine Test & Inspection

SC JKT need to conduct several routine testing and inspections, both in batching plants by
witness or in independent laboratory based on QC-Concrete-STD-JD03 forms as below
listed:
9
Monthly Tests & Inspections
SC JKT shall review batching plant process through inspections and confirmed material
quality (fine and coarse aggregate) through direct test witness and sampling in
batching plant.
SC JKT shall review Cement, Fly ash and Admixture quality through test result analysis.
6-Monthly Tests & Inspections
SC JKT shall review batching plant facilities condition through inspections and
confirmed material quality (fine and coarse aggregate) through independent
laboratory test.
Annual Test & Inspection
SC JKT shall confirmed water and cement quality through independent laboratory test.
1.3 REQUIREMENTS
1.3.1 CONCRETE PRODUCTION

a) Batching Plant Raw Materials
All concrete suppliers raw materials shall meet SC JKT standard requirement as stated on
QC-Concrete-STD-RQ01.
b) Batching Plant Facilities
All concrete suppliers facilities shall meet SC JKT standard requirement as stated on QC-
Concrete-STD-RQ02.
c) Batching Plant Process
All concrete suppliers facilities shall meet SC JKT standard requirement as stated on QC-
Concrete-STD-RQ03.
1.3.2 CONSTRUCTION
a) Concrete Mix Design
SC JKT mix design shall meet requirement as stated on QC-Concrete-STD-RQ04 as below
listed:
Table 1.1 Requirement of Mix Design Proportion
No. Items Requirements
1 Water Cement Ratio General < 65%
Around 42 MPa ~ 41%
Around 35 MPa ~ 48%
Around 28 MPa ~ 57%
2 Cement Content Min. 300 kg/m3
3 Water Content Max. 185 kg/m3 (target ~165 kg/m3)
4 Sand Aggregate Ratio 45±3 %
5 Fine Aggregate No Manufactured sand
6 Coarse Aggregate Max. Size 25 mm
7 Admixture Designated admixture and setting time shall
be clearly mentioned
b) Concrete Control and Monitoring

SC JKT project concrete person in charge shall follow standard requirement as stated on
QC-Concrete-STD-RQ05. Acceptance of 28 days concrete compression result shall be
based on SNI 03-2847-2013 as follow:
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Table 1.2 Concrete Strength Acceptance Rules
No. Items Description
1 Individual result of cylinder test No individual strength test ≤ Fc - 3,5MPa
2 Consecutive result of cylinder Average of 3 consecutive strength test t
test Fc
Monitoring of concrete compression strength results is compulsory for every grade and
every supplier. The aim is to understand the performance of batching plant in producing
good and steady concrete quality. Whenever suspicious results are appear, it can be
detected immediately and construction team may take action to study the conditions in
purpose to prevent serious problems.
Actual results shall be monitored compare to designated F c, required average strength Fcr
and actual average strength results.
Figure 1.1 Sample of Concrete Strength Monitoring
1.4 ACTIONS TOWARDS INSUFFICIENCY

When there is insufficiency during construction stage, action shall be taken in the following
manners. Notice of Improvement and Non-conformance report shall be issued and followed up
based on below flow chart before proceed to the next casting.
11
Chart 1.3 Flow Chart of Action towards Insufficiency
1.4.1 JUDGMENT
Project concrete person in charge will conduct routine inspections and testing based on
the requirements to confirm concrete quality.
Notice of Improvement (NOI) may be issued by project concrete person in charge if they
found any discrepancy during the inspection. They will contact the batching plant QC in
charge to do improvement and/or rectification to overcome the problems.
Non-Conformance Report (NCR) may be issued by project QC manager or SC JKT QC
Section if in any cases major critical discrepancy found or if batching plant cannot
improve or rectify NOI issued by project concrete person in charge.
1.4.2 TOLERANCE
For mix design composition and compressive strength, tolerance shall follow SC JKT
standard as mention on part 1.3.2.
For material specification and properties other than strength, allowable tolerance shall
be reviewed from previous numbers of test data. If several data are out of criteria, there
is still a chance to accept it. Acceptance number of conformity criteria shall be as below:
12
Table 1.3 Acceptance Number for Conformity Criteria. (Adapted from Singapore standard SS EN 206-1:2009)
Number of Test Acceptance Numbers
Results (of insufficient results)
1-2 0
3-4 1
5-7 2
8-12 3
13-19 5
20-31 7
32-49 10
50-79 14
80-100 21
1.4.3 ACTIONS
The following actions shall be taken in the event of non-conformity:
If the non-conformity is confirmed, in example by retesting, take corrective actions
including a management review or relevant production control procedure.
Where there is confirmed non-conformity with the specification that was not obvious at
delivery, give notice to concrete supplier in order to avoid any consequential damage.
Record actions on the items above
13
2 CONCRETE RAW MATERIALS
14
4
2.1 BOTTOM LINE REQUIREMENTS
No Material Check Items Requirement

FINESESS MODULUS (FM) Max. 8%
CLAY CONTENT Max. 5%
MATERIAL FINER THAN 200 SIEVE Max. 1%
COARSE AGGREGATE SIEVE
(ASTM C33) (1 1/2-in) 37.5-mm 100%
1 (1-in) 25mm 95%-100%
(1/2-in) 12.5mm 25%-60%
(No. 4) 4.75mm 0%-10%
(No. 8) 2.36-mm 0%-5%
RELATIVE DENSITY (SPECIFIC GRAVITY) OD >2.5
WATER ABSORBTION 4%
FINESESS MODULUS (FM) 2.3-3.1
CLAY CONTENT Max. 3%
MATERIAL FINER THAN 200 SIEVE Max. 3%
SIEVE
FINE AGGREGATE
(3/8-in) 9.5-mm 100&

(ASTM C33)
(No.4) 4.75-mm 95%-100%

2 (No. 8) 2.36-mm 80%-100%
(No. 16) 1.18-mm 50%-85%
(No. 30) 600-mm 25%-60%
(No. 50) 300-mm 5%-30%
(No. 100) 150-mm 0-10%
RELATIVE DENSITY (SPECIFIC GRAVITY) OD >2.5
WATER ABSORBTION Max. 4%
CHEMICAL REQUIREMENTS
MgO (max %) 6
SO3 (max %)
C3A ≤ 8% 3
C3A > 8% 3.5
Loss on Ignition (max %) 5
CEMENT (OPC Type 1)
(SNI 02-2834-2000)
Insoluble Residue (max %) 3

Equivalent Alkalies, as Na2O, etc. (max %) 0.6
PHYSICAL REQUIREMENTS
3
Air Content (max %) 12
Strength (min)
3 days 125 (kg/cm2)
7 days 200 (kg/cm2)
28 days 280 (kg/cm2)
Autoclave expansion Max. 0.8%
Time of Setting
Initial 45 minutes
Final Max. 375 minutes
15
No Material Check Items Requirements
SiO2+Al2O3+Fe2O3 (min %) 70
SO3 (max %) 5
Moisture Content (max %) 6
Equivalent Alkalies, as Na2O, etc. (max %) 1.5
(SNI 03-2460-1991)
Specific Surface* (test required for
FLY ASH
adjustment)
4
Finesess (max %) 34
Strength Activity Index
7 days (min %) -
28 days (min %) 75
Water Req. (max %) 105
Autoclave expansion (max %) 0.8
Uniformity Requirements
Desity (max variation %) 5
5
Chloride Cl, ppm
Pre-stressed concrete/bridges 500
(SNI 7974:2013)
Other RC in moist environment containing 1000

aluminum embedment or dissimilar
WATER
5 metals
Sulfate as SO4, ppm 3000
Alkalies as (Na2O+0,658K2O), ppm 600
Total solids, ppm 50000
PHYSICAL REQUIREMENTS Potable, no smell,
no color
DOSAGE
Trial Result Slump & Strength
for designated
dosage shall be
confirm through
ADMIXTURE
trial test prior to

6 trial mix execution
Dimension of Dosage Table of admixture
dosage for batching
control used shall
be based on volume
(lt) not by weight
(kg)
16
2.2 MATERIAL SOURCES
2.2.1 Fine Aggregate

a) Bangka/Belitung
Figure 2.1 Quarry location and visual samples of Bangka sand
Bangka/Belitung sand quarry is Located in Bangka & Belitung Island, east of Sumatra. The
sand is get from ex- tin mining. Color of materials is white, with not so much organic
content. It is recommended to use due to good record of projects performance using this
sand. Cracks are less appears comparing to other sand used.
Table 2.1Material Characteristic of Bangka/Belitung San
Sample Source (non-washed sand)
Batching Plan Adhimix Jayamix Pionir PAP PAP
T. Abang Kb. Nanas Kasa Bangka Belitung
Specific Gravity
Dry 2.53 2.53 2.56 2.58 2.57
SSD 2.56 2.57 2.59 2.62 2.60
Water Absorption, % 1.16 1.41 1.00 1.26 0.99
Finesses Modulus (FM) 2.75 3.13 2.85 2.43 2.89
Material Finer than - - - 4.66 2.30
No.200, %
Testing Lab.: Shimizu Institute; Sampling: Shimizu Corp. JKT;
In addition, one of quarry in Bangka is producing washed sand, with more bright color
and less of organic content. This sand quality is very excellent and compatible to use for
high-strength concrete. Below are comparisons between the two sands according to
characteristic:
Items Non-Washed Washed
Appearances
Specific Gravity
Dry 2.58 2.60
SSD 2.62 2.62
Water Absorption, % 1.26 0.72
Finesses Modulus (FM) 2.43 2.77
Material Finer than No.200, % 4.66 3.41
Testing Lab.: Shimizu Institute; Sampling: Shimizu Corp. JKT; Source: PAP Tanjung Priok Stockyard
17
b) Lampung
Figure 2.2 Quarry location and visual samples of Lampung sand
Lampung sand quarry is Located in Sumatra Island. Color of materials is dark grey. This
material usually use for retail housing project and not recommended to use on structural
ready mix concrete because of suspected to have unacceptable organic impurities. So far,
we have no experience on using Lampung Sand for our concrete. However, from Shimizu
institute test results below, material characteristic are still acceptable to be use.
Table 2.2 Material Characteristic Lampung Sand
Specific Gravity
Dry 2.56
SSD 2.59
Water Absorption, % 0.98
Finesses Modulus (FM) 2.00
Material Finer than No.200, % 3.97
Testing Lab.: Shimizu Institute; Sampling: Shimizu Corp. JKT; Source: PAP Tanjung Priok Stockyard
c) Pontianak
Figure 2.3 Quarry location and visual samples of Pontianak sand
Pontianak sand quarry is Located in Kalimantan Island. The sand is get from the
downstream of Kapuas River. Color of materials is brown. Judging from its material
characteristic, this sand is averagely good. Water absorption is not too high, still below
2.5% and clay content is very low, nearly in same quality with Bangka/Belitung Sand.
Table 2.3Material Characteristic of Pontianak Sand
Specific Gravity
Dry 2.65
SSD 2.66
Testing Lab.: University of Indonesia; Sampling: Shimizu Corp. JKT; Source: Torsina Pulogadung Stockyard
18
d) Ketapang
Figure 2.4 Quarry location and visual samples of Ketapang sand
Ketapang sand quarry is Located in Kalimantan Island. The sand is get from downstream
area of Pawan River. Color of materials is light white, almost similar with
Bangka/Belitung. The materials looks clean, however it contains above 4% material finer
than no.200 sieve. If this material could improve the content of material finer than sieve
no.200, then it is recommended to use.
Table 2.4 Material Characteristic of Ketapang Sand

Specific Gravity
Dry 2.61
SSD 2.63
Testing Lab.: University of Indonesia; Sampling: Shimizu Corp. JKT; Source: Marunda Port Stockyard
e) Cimalaka
Figure 2.5 Quarry location and visual samples of Cimalaka sand
Cimalaka sand quarry is Located in west java area. The sand is get from Tampomas
Mountain. Color of materials is dark brown. Cimalaka sand is not natural sand, it
produced from crushed stone. Texture of materials is rough.
This material is not recommended to use due to high water absorption characteristic.
Especially in wide surface casting area such as slabs or walls, it is better to avoid using
Cimalaka Sand because the cracks are tent to occur.
19
Table 2.5 Material Characteristic of Cimalaka Sand
Supplier Adhimix Torsina Torsina
Batching Plan Dawuan Cibatu Kalijati
Specific Gravity S1 S2 S1 S2 S1 S2
Dry 2.35 2.40 2.45 2.46 2.33 2.31
SSD 2.49 2.52 2.56 2.56 2.48 2.47
Water Absorption, % 6.00 5.23 4.45 4.10 6.47 6.85
Finesses Modulus (FM) 3.72 3.39 3.12 3.31 3.46 3.52
Material Finer than - - - - - -
No.200, %
Testing Lab.: Shimizu Institute; Sampling: Shimizu Corp. JKT;
f) Boyolali
Figure 2.6 Quarry location and visual samples of Boyolali sand
Boyolali sand quarry is Located in Central Java Area. The sand is get from old
sedimentation of Merapi Mountain explosion. Color of materials is almost black. Good
sand are found after more than 5m depth excavation. Top layer sand is mixed with soil.
This kind of material are not recommended to use.
Table 2.6 Material Characteristic of Boyolali Sand
Specific Gravity
Dry 2.20
SSD 2.24
Clay
Clay Lumps, % 2.50
Finer than No.200, % -
Testing Lab.: Universitas Diponegoro; Sampling: Shimizu Corp. JKT
g) Weleri
Figure 2.7 Quarry location and visual samples of Weleri sand
20
Figure 2.8 Weleri sand stone and crusher on quarry
Weleri sand quarry is Located in Central Java area. The sand is get from crushed dense
sand stone. Color of materials is almost black. This kind of material are not recommended
to use.
Table 2.7 Material Characteristic of Weleri Sand
Specific Gravity
Dry 2.48
SSD 2.52
Clay
Clay Lumps, % 3.75
Finer than No.200, % -
Testing Lab.: Universitas Diponegoro; Sampling: Shimizu Corp. JKT
21
2.2.2 Coarse Aggregate
a) Rumpin
Rumpin is Located in south of Jakarta area. The stone is get from Sindur Mountain. In
Rumpin area, there are many stone quarries located nearby. Nevertheless, the
characteristic are varies within different area. Some part of mountain produced light
coarse aggregates which may be harmful for concrete while some others are producing
good quality of material. Below are detail explanations for some quarries that supply
coarse aggregates to concrete ready mix suppliers.
Figure 2.9 Rumpin area location
Figure 2.10 Several Quarries in Rumpin
22
¾ Pion Quarry Nusantara
Figure 2.11 Visual appearances of Pion’s produced coarse aggregate
General Notice:
Pion quarry belongs to PT SCG Jaya Ready-Mix or Jayamix Beton. Pion’s aggregates,
at the time of quarry visit, are having problems with its grading. Due to broken cone
crushers, the produce aggregates with some rounded and flaky shapes which is not
good for concrete. The size is also disturbed. Some stones are beyond the maximum
size of 25mm. There is no water washing in the process of crushing, therefore the
aggregates are dusty.
However, material properties are quite good and acceptable. If they can improve
grading problems, materials from this quarry are recommended to use.
Table 2.8 Material Characteristic of Pion Sand from Quarry
Specific Gravity
Dry 2.58
SSD 2.63
Water Absorption, % 1,87
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp. from quarry
Specific Gravity Sample 1 Sample 2

Dry 2.55 2.53
SSD 2.61 2.60
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp. from Jayamix Kebon Nanas
batching plant
¾ Kusumo
Figure 2.12 Visual appearances of Kusumo’s produced coarse aggregate
23
General Notice
Kusumo’s aggregates are having problems with its grading. The size is disturbed due
to inappropriate usage of screen mesh. Some stones are beyond the maximum size
of 25mm. There is no water washing in the process of crushing, therefore the
aggregates are dusty.
However, the stone was in good quality. There is no porous on the surface which is
good to prevent shrinkage behavior. If they can improve grading problems and material
cleanliness, materials from this quarry are recommended to use.
Table 2.9 Material Characteristic of Kusumo Aggregate
Specific Gravity
Dry 2.56
SSD 2.62
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp. from quarry
¾ Batu Gunung Makmur (BGM)
Figure 2.13 Visual appearances of BGM’s produced coarse aggregate
Figure 2.14 (Left)Porous surface of aggregate; (Right) Screen mesh, size 30mm by 30mm for maximum
aggregate size 25mm
General Notice:
BGM’s aggregates, at the time of quarry visit, are having problems with its grading.
The size is disturbed due to inappropriate usage of screen mesh. Some stones are
beyond the maximum size of 25mm because the screen size was 35mm by 35mm.
There is no water washing in the process of crushing, therefore the aggregates are
dusty. In addition, almost same case with Pion’s, the stone have porous surface
24
which may lead to high water absorption that may be harmful for concrete
shrinkage behavior. Materials from this quarry are not recommended to use.
Table 2.10 Material Characteristic of BGM Coarse
Specific Gravity
Dry 2.48
SSD 2.56
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp from quarry.

Dry 2.61 2.53
SSD 2.65 2.60
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp. from Adhimix Tanah Abang
batching plant
¾ Sudamanik
Figure 2.15 Visual appearances of Sudamanik’s produced coarse aggregate
General Notice:
Sudamanik aggregates are having the best quality at grading in Rumpin area. The
size is very uniform. This was usually used for high strength concrete in Jakarta area.
Unit price is about 10% higher than aggregates from other quarries.
However, Just like other quarries surrounds, there is no water washing in the
process of crushing, therefore the aggregates are dusty. Since the location of
mountain just besides BGM’s, the stone also have porous surface which may lead to
high water absorption that may be harmful for concrete shrinkage behavior. If they
can improve cleanliness, it is recommended to use.
Table 2.11 Material Characteristic of Sudamanik Course
Specific Gravity
Dry 2.50
SSD 2.58
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp.from quarry
b) Purwakarta
Purwakarta is Located in east of Jakarta area. In Purwakarta area, there are many stone
quarries located nearby. Generally, aggregates come from this area are not better than
Rumpin due to very high water absorption characteristic and some light aggregates.
25
Surface of aggregates are porous. This condition often leads to concrete cracking in some
of our projects at industrial estate where all the concrete suppliers get coarse aggregate
from Purwakarta area. Below are detail explanations for some quarries that supply coarse
aggregates to concrete ready mix suppliers.
Figure 2.16 Purwakarta area location
¾ BCA Quarry
Figure 2.17 Visual appearances of BCA’s produced coarse aggregate, picture taken in Adhimix Dawuan Plant
General Notice:
As seen on the picture above, the stone appearances are porous and dusty. Some
flaky shapes are found. However, material characteristic are acceptable so it is ok
to use this materials.
Table 2.12 Material Characteristic of BCA Course
Specific Sample 1 Sample 2 Sample 1 Sample 2
Gravity Adhimix Adhimix Pionir Pionir
Dawuan Dawuan Karawang Karawang
Dry 2.51 2.52 2.49 2.46
SSD 2.59 2.60 2.56 2.54
Water Absorption, % 3.39 3.15 3.08 3.06
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp.
26
¾ MSS Quarry
Figure 2.18 Visual appearances of MSS’s produced coarse aggregate, picture taken in MSS Quarry
General Notice:
As seen on the picture above, gradation of coarse aggregate seems good. Color also
uniformly grey, no light brown colors appear. However, the have some flaky shape
in some part.
Table 2.13 Material Characteristic of MSS Course
Specific Gravity
Dry 2.41
SSD 2.47
Testing Lab.: University of Indonesia, Jakarta; Sampling: Shimizu Corp. from quarry
¾ Cibogo
Figure 2.19 Visual appearance of Cibogo Quarry (Left) Aggregate varies in colors, light browns are light
aggregates’ color; (Right) porous surface of aggregate
General Notice:
As seen on the picture above, the stone appearances are dusty and porous. Size
distribution is also not good. Some parts are too small and some others are too big.
Flaky shapes are found. Light brown colors that usually indicate light weight
aggregates are appear. Test results from samples also shown that specific gravity of
dry condition is less than required 2,5. Water absorptions are far over 4%. This
aggregate is very not recommended to use because it may lead to major shrinkage
behavior or even may affected structural strength.
Table 2.14 Material Characteristic of MSS Coarse
Dry 2.29 2.30
SSD 2.44 2.44
Testing Lab.: Shimizu Institute Lab, Tokyo; Sampling: Shimizu Corp.
27
c) Jepara
Figure 2.20 Jepara area location and Crusher at Calvary Quarry
Jepara is Located in north of Semarang area. Most of batching plant around kudus coarse
aggregate materials supplied by PT Calvari Abadi which located in Jepara. They have 2
crushers and produce 2 sizes of aggregates. First size distribution is from 5mm-10mm
which they called screening and the other one is from 10mm-20mm which called split
and generally used for concrete production. Screen mesh size for split production was
1”x1” square.
Figure 2.21 Screening material of 5mm-10mm and coarse aggregate material of 10mm-20mm
Generally, aggregates come from this area are very dusty and dirty. Many small particles
are inside the aggregates. Stones are coming from land area below farming field, so it is
mostly contaminated by soil. There are also many rounded shapes stones passes the
screen mesh.
Figure 2.22 Location of stone source for coarse aggregate production in Jepara
Particularly, dirty condition will somehow change the sand/aggregate ratio on the mixing
design which will lead to high possibilities of cracks.
28
Table 2.15 Material Characteristic of Jepara Course
Specific Gravity Quarry Batching
Plant
Dry 2.73 2.73
SSD 2.77 2.75
Testing Lab.: Diponegoro University; Sampling: Shimizu Corp.
2.2.3 Fly Ash

a) Material Source & Production
Figure 2.23 Suralaya power plant location map
For Jakarta to West Java Region, all fly ash supplied and produce by Suralaya Power Plant.
Located in the very west of Java Island, this power plant received coals from Sumatra and
Kalimantan Island. Coals from Sumatra are better in quality because it is older than the
one from Kalimantan. It has 7 chimneys as shown at the pictures below.
Figure 2.24 Suralaya power plant chimneys
All the produced fly ash from 7 chimneys is stored in 2 big silos. They have ash catcher at
the top of chimneys and the fly ash will brought down and shot to silos through pipes.
Every fly ash suppliers take the material from the silo and delivered to concrete batching
plants in all over Jakarta and West Java region.
29
Figure 2.25 Silos of fly ash
b) Material Characteristic
Fly ash from Suralaya power plant is classified as class F according to ASTM C618. The
minimum content of total silica as SiO2, Aluminum as Al2O3 and Ferro as FE2O3 is 70%.
Below are summary of test result conducted by fly ash suppliers each month.
Table 2.16 Test result summary from fly ash suppliers
Equivalent
Sio2+AL2O3 Moisture Loos on
Concrete SO3 Alkalies, as
No Test Date +Fe2O3 Content Ignition
Supplier Na2O ect
(min 70%) (max 5%) (max 6%) (max 3%) (max 1,5%)
1 Adhimix 6/5/2015 91.66 0.15 0.53 0.62 -
2 Jayamix 3/3/2015 79.26 1.1 0.45 1.24 4.1
3 Jayamix 2/16/2015 84.84 0.46 - 1.15 1.3
4 Pionir 6/1/2015 78.24 0.43 0.48 0.49 0.86
5 Pionir 4/21/2015 81.92 0.54 0.4 0.69 <0,01
6 Pionir 7/18/2014 84.86 0.33 0.56 1.27 1.77
7 Pionir 8/13/2014 77.4 1.08 0.36 0.32 2.45
8 Pionir 9/15/2014 79 0.59 0.44 1.38 0.74
9 Pionir 10/17/2014 86.87 0.33 0.34 2.14 0.75
10 Pionir 11/19/2014 76.8 0.56 0.36 0.58 3.13
11 Pionir 12/15/2014 84.17 0.55 0.52 0.77 2.23
12 Pionir 1/23/2015 74.39 0.62 0.34 0.45 1.5
Karya
13 Beton 1/23/2015 74.39 0.62 0.34 0.45 1.5
30
3 CONCRETE PRODUCTION CONTROL
31
3.1 BOTTOM LINE REQUIREMENT OF BATCHING PLANT FACILITIES
No FACILITIES Check Items Requirement

STOCK PILE
Compartments Fully separated, No contamination
Concrete floor or 30cm from bottom part
material shall not be used
SILOS
MATERIAL STOCK
Material Weather proof, no rust, no damage
Hooper Efficient discharge, not exceed allowable
1 tolerance,
Shall be calibrated once in 6 months
Cement ±1%
Fly Ash ±1%
WATER TANK
To meet day-to-day needs (BP capacity of
Capacity production)
Condition No contamination
MOISTURE TEST
Total Moisture
Oven Ventilated oven. Capable to maintain
temperature 110±5oC.
If use microwave oven, container shall be
non-metallic material. Temperature above
110oC
Frying Pan May be used for small quantity of testing,
Use hot plate
TESTING TOOLS & EQUIPMENT
Surface Moisture
2 Flask; Glass or non-corrosive metal. Scale
pycnometer increment 0.5ml or less. Volume capacity
shall be 2-3 times sample volume.
SIEVE ANALYSIS
Coarse Aggregate
Sieve Number
Fine Aggregate
Sieve Number
32
No Facilities Check Items Requirements
CLAY CONTENT
Balance Sensitivity 0.1% of total mass
Containers Anti-rust material
Drying Oven Ventilated oven. Capable to maintain
If use microwave oven, container shall be
non-metallic material
Relative Density (Specific
Gravity)
Balance Accurate to 0.05kg
Tamping Rod Dia.16mm, Length 600mm
Measure Cylindrical metal container
Scoop Convenience with aggregates size
Plate Glass 6mm Thick, 25mm larger than measure
diameter
WATER ABSORBTION
2
Balance Sensitivity 0.1gr or less,
capacity 1kg or more
Pycnometer/Flask Capacity ±100mm3, 50% more than samples
volume
Mold & Tamper Made of steel, Thickness 0.8mm, Inner top
dia. 40±3mm, Inner bot dia. 90±3mm,
Height 75±3mm
SLUMP TEST
Cone
Plate Thickness t1,5mm, good condition of

flatness
Stick Diameter 16mm, length 600mm
33
TEMPERATURE
Thermometer Scale readable to 0.5oC increment throughout
a range of 0-50oC
Shall be calibrated annually
SAMPLING
Cylinder
Stick Dia. 10±2mm, Length 300±100mm

No leakage, all specimen shall be fully cured
Pond under water
COMPRESSIVE STRENGTH
TEST
Machine Capacity of stress shall be more than
designated concrete strength,
Scales to return to zero
Apply load continuously without shock,
BINS
Separator Fully separated, No contamination, No
overflow to conveyor belt
signage to indicate usage of bins for every
Marking material type
BATCHING TOOLS & EQUIPMENT
Screen Mesh 100mmx100mm screen on top of bins

3 Hooper Efficient discharge, not exceed allowable
tolerance Agg. ±2%
CONVEYOR BELT Shall be free from other substance except
particular materials that being weight
WEIGHING CONTROL / Shall be calibrated once in 6 months,
SCALES Allowable tolerance:
Agg. ±2%; Cement/FA ±1%; water ±1%;
Admixture ±3%
DISPENSER FOR ADMIXTURE Shall be separated for each of admixture type,
Shall be controlled flow (computerized)
Clear mark for scale
Start from zero while loading
34
WATER TANK Calibrated flow meter (computerized)

Thickness of wall shall be confirmed to hold
water pressure,
Free of contamination
MIXER Provided with acceptable timing device that
3 will not permit the batch to be discharge
before the specified mixing time has elapsed;
Volume capacity shall be 37% more than
TRUCK MIXER
concrete volume
Cleanliness shall be maintained
Cover shall be provided
Mixing revolution 70-100
WEIGHING CONTROL / once in 6 months, data to be submitted to
SCALES SHIMZ
CALIBRATION &
CERTIFICATION
DISPENSER FOR ADMIXTURE annually, data to be submitted to SHIMZ

4
MACHINE annually, data to be submitted to SHIMZ
THERMOMETER annually, data to be submitted to SHIMZ
once in 6 months, data to be submitted to
LABORATORY BALANCE
SHIMZ
35
3.2 BOTTOM LINE REQUIREMENT OF BATCHING PLANT PROCESS
No PROCESS Check Items Requirement

COARSE AGGREGATE
MATERIAL DELIVERY CHECK

Visual Check Comply with master sample, No discrepancy in
color, shape and size
Clay Content Comply with specification mention on '(BP)Raw
Material' section
1 FINE AGGREGATE
Visual Check Comply with master sample, No discrepancy in
color, shape and size
Clay Content Comply with specification mention on '(BP)Raw
Material' section
MOISTURE CONTENT
Total Moisture or Surface 2 times a day + after raining;
Moisture
SIEVE ANALYSIS Comply with specification mention on '(BP)Raw
Material' section;
Frequency: once a month;
No wash out, Done in dry condition
RELATIVE DENSITY (SPECIFIC Comply with specification mention on '(BP)Raw
GRAVITY) Material' section;
REGULAR TESTING
Frequency once a month;

Done both dry and SSD condition
2
WATER ABSORBTION
Coarse Aggregate Comply with specification mention on '(BP)Raw
Material' section;
Fine Aggregate Comply with specification mention on '(BP)Raw

Material' section;
Frequency: once a month
FLY ASH SEDIMENT TEST Not more than 55mm;

36
Requirements
No Process Check Items
WATER CONTENT Based on moisture content results,

ADJUSTMENT every batch
MATERIAL ADDITION Addition of all ingredients shall be done in
computerize system within tolerance
Coarse Aggregates ±2%
Fine Aggregates ±2%
Cement ±1%
BATCHING
Fly Ash ±1%

3 Water ±1%
Admixture ±3%
MIXING
Timing Not less than 1.5 minutes for 1m3, and additional
0.5 minutes for every 1m3 volume addition
Concrete Condition Capable of achieving a uniform distribution of the
constituent materials, and a uniform consistence
of the concrete
TRUCK LOADING No water inside before concreate loading
SLUMP TEST Comply with mix design;
Before delivery of every 7 truck mixer
TEMPERATURE CHECK Max. 10oC above ambience temp.;
Complete temp. measurement within 5 minutes
after obtaining the samples;
Before delivery of every 7 truck mixer
SAMPLING
Procedure The elapsed time shall not be exceed 15min after
obtain the first & final portions of sample
Cylinder Numbers 2 samples min for each purpose of testing. (i.e. 2
for 7 days, 2 for 28 days, 2 for spare, etc.) for one
set of samples
AFTER BATCHING
Representative Amount A set of samples represent 115m3 volume or

465m2 surface, taken from one truck mixer
4 SPECIMEN CURING
Pond No leakage, all specimen shall be fully cured under
water
Location Free from vibration and from direct sun light
Temperature Ambiance
Preparation Machine gauge shall be at zero
Capping Shall be as followed:
Placement Specimen shall be placed at the center of machine
37
3.3 BATCHING PLANT REFERENCES
3.3.1 Adhimix in Jakarta Area

a) Adhimix Tanah Abang Plant
Located on Jl. Tembus Fachrudin No. 40 Jati Baru – Tanah Abang – Jakarta Pusat.
Figure 3.1 Adhimix Tanah Abang Plant Location Map & Condition
Production Information
Batching Plant Area 6365 m2
Material Storage Area 2000 m2
Production Capacity 80 m3/hour
Number of Truck Mixer 24 Trucks
Mixing Type Wet
Mixer Batch Capacity 3,5 m3/batch
Laboratory Facilities Information

Compressive Test Machine 1 Unit
Sieve Shaker 1 Unit
LossAngeles Machine 1 Unit
Penetrometer Setting Time 1 Unit
Air Content Test 1 Unit
Thermometer 1 Unit
Chloride Test 1 Unit
Scale Lab 3 Unit
Mold Cylinder 15x30 180 Unit
Mold Cylinder 10x20 30 Unit
Slump Test Set 8 Unit
Material Sources
Cement Location: Cibinong
Supplier: Indocement
Fly Ash Location: PLTU Suralaya
Supplier: Sinar Fajar Utama
Coarse Aggregate Location: Rumpin – Bogor
Supplier: BGM, BSM, Musika
Fine Aggregate Location: Bangka, Belitung
Supplier: Jabel, KTP, Irpau
38
Previous Shimizu Projects Experiences
Project Year
Shimizu-Total, Jo Menara Astra 2014-present
Shimizu-Total, Jo MNC Media 2014-present
Quality Notice
o Concrete Segregation
Figure 3.2 Condition of Concrete Segregation
Concrete segregation may lead to honeycombs and cracking problems of the final
product. The occurrence of problems is caused by several factors. Below are
probable causes and action taken on mentioned batching plant to overcome
problems.
No. Problems Action Taken
1 Inappropriate grading of both Control material grading with
coarse and fine aggregate size routine sieve analysis check
2 Insufficiently excess water on
the mixing:
x There is water standing x Do reverse spin of mixer
on the agitating truck truck before loading to take
mixer before the fresh out standing water
concrete pour inside
x Rain water comes to x Put cover on truck mixer
while deliver to site
3 Inadequate time on mixing Control mixing time as per our
(too short or too long) requirement; 1,5 minutes/m3
and another additional 0,5
minutes for every m3 addition
o Leakage on Admixture Dispenser Valve
Figure 3.3 Condition of Admixture Dispenser & Concrete Long Setting on Slab in Shimizu Project
Leakage of dispenser valve caused over addition of admixture. As the valve

broken, the automatic system will continue to fill in the dispenser because it will
not reach the required value. Due to the overdose of admixture, concrete are
failed to set (long setting).
39
No Problems Action Taken
1 Technical problems on Conduct periodic inspection of
batching equipment admixture dispenser w/ supplier
b) Adhimix Taman Anggrek Plant
Located on Jl.Orchid Raya No.1 Tanjung Duren Grogol Jakarta Barat.
Figure 3.4 Adhimix Taman Anggrek Plant Location Map & Condition
Production Capacity 50 m3/hour (Dry)
70 m3/hour (Wet)
Number of Truck Mixer 25 trucks
Mixing Type Dry and Wet
Mixer Batch Capacity 3,5 m3/batch (Dry) 2,5 m3/batch(Wet)

Compressive Test Machine 1 unit
Sieve Shaker 1 unit
Air content 1 unit
Oven dry 1 unit
Speedy moisture 1 unit
Digital balance 1 unit
Balance 50 kg 1 unit
Thermometer 3 unit
Slump cone and stick 3 set
Cylinder mold 50 pcs
Material Sources
Supplier: BGM
40
Project Year
Toto New Office 2015-present
Quality Notice
o Concrete Segregation
Figure 3.5 Condition of Concrete Segregation from Taman Anggrek Plant
As in Adhimix Tanah Abang Plant, Taman Anggrek Plant also suffers concrete
segregation problems. Please refer to previous section for detail explanation.
o Separation on Material Stock & Bins
Figure 3.6 Condition of Material Bins & Stockpiles without Appropriate Separation
Mixed material type and size may affect the mix proportion, such as S/A ratio,
which may lead to concrete segregations, cracking and other problems.
1 Weighing bin separation Improve the bin separator to the
(Natural sands and M Sands) expected height, prevent
is not high enough, material material intermingled.
could be intermingled during
loading process (dry mix bin)
(Condition after improvement)

2 No separation between Provide the wall separation
coarse aggregate stock pile. between material stockpiles.
Contamination may occur.
41
c) Adhimix Lenteng Agung Plant
Located on Jalan Raya Lenteng Agung No.50 Lenteng Agung,Jagakarsa, Jakarta Selatan.
Figure 3.7 Adhimix Lenteng Agung Plant Location Map & Condition
Material Storage Area 10.000 m2
Mixing Type Dry and Wet

Sieve Shaker 1 unit
Oven dry 1 unit
Speedy moisture 1 unit
Material Sources
Supplier: BGM
Previous Shimizu Experience Project

Project Year
YKK 2009
GTU Simatupang 2013-2015
42
Quality Notice
o Over Dosage of Admixture
Figure 3.8 Long Setting on Column in Shimizu Project Supplied by Adhimix Lenteng Agung
Over addition of admixture may cause concrete long setting. In this case, there
are several problems occurs on batching plant as below.
1 Admixture weighing by Establish fully computerized
manual system. Human error batching system, including
cause big variation. addition of admixture, eliminate
human error.
2 Miss-conversion of admixture Provide dosage table together
dosage from weight to with admixture supplier on
volume batching plant to easy checking
during batching time.
3.3.2 Adhimix Outside Jakarta Area

a) Adhimix Cibitung Plant
Located on Jalan Raya Fatahillah Km 49, Cibitung, Bekasi.
Figure 3.9 Adhimix Cibitung Plant Location Map
Batching Plant Area 12.500 m2
Mixing Type Wet system
Mixer Batch Capacity 3m3/batch
43
Sieve Shaker 1 unit
Laboratory balance 1 unit
Pycnometers, cone & stick 1 unit
Slump cone & stick 3 unit
Cylinder mold 30 unit
Beam mold -
Weight scale 50 kg 1 unit
Speedy moisture content 1 unit
Material Sources
Coarse Aggregate Location: Purwakarta
Supplier: BCA
Fine Aggregate Location: Cimalaka
Supplier: RDR

Project Year
T-Tec 2012
Usui 2012
Tsuchiya 2013
NT Indonesia 2013
Sugity 3 2013
Toyoriko 2014
JFE 2014
Quality Notice
o Raw Material Issues
Raw Material problems may lead to concrete durability and performance, such as
concrete shrinkage. Based on material test result, below are some problems on
raw material from sources that used by Adhimix Cibitung.
44
1 High water absorption No action has been taken.
materials. Based on shimizu However, for industrial park
institute test result, sand are area, this batching plant is not
above 5% and coarse allowed to cast wide surface
aggregate are above 3%. area such as slab and wall
because shrinkage cracks will
occur.
If there is no other option, it is
suggested to select raw material
from another sources such as
Bangka/Belitung with some
impact on concrete price.
b) Adhimix Dawuan Plant

Located on Kawasan Industri Kujang Cikampek (KIKC) Kav.7/4a. Jl. Akses Tol Dawuan-
Cikampek.
Figure 3.10 Adhimix Dawuan Plant Location Map & Condition
Mixing Type Wet
Mixer Batch Capacity 2 m3/batch

Sieve Shaker 1set
Laboratory balance 1 set
Pycnometers, cone & stick 1 set
Slump cone & stick 8 set
Beam mold 12 pcs
Weight scale 50 kg 1 unit
Speedy moisture content 1 unit
45
Material Sources
Supplier: BCA
Supplier: RDR

Project Year
Nipro Indonesia Jaya 2010
Proctor & Gamble 2011
Nissan Motor Indonesia 2012
G TEK - I 2012
HPPM 2012
HPPM QC 2013
G TEK – II 2014
SUAI 2014
BBRAUN 2015
Quality Notice
Figure 3.11 Condition of Material Bins & Stockpiles without Appropriate Separation
1 Weighing bin separation is Improve the bin separator to the
not high enough, material expected height, prevent
could be mixed during material mixed.
loading process (dry mix bin)
46
No separation between Provide the wall separation
2 coarse aggregate stock pile. between material stockpiles.
Figure 3.12 Bad Coarse Aggregate Grading on Adhimix Dawuan
concrete shrinkage. Below are some problems on raw material that found in
Adhimix Dawuan plant.
1 Inappropriate grading of both Control material grading with
coarse and fine aggregate routine sieve analysis check
size.
2 High water absorption No action has been taken.
materials. Based on shimizu However, for industrial park
institute test result, sand are area, this batching plant is not
above 5% and coarse allowed to cast wide surface
aggregate are above 3%. area such as slab and wall
because shrinkage cracks will
occur.
If there is no other option, it is
suggested to select raw material
from another sources such as
Bangka/Belitung with some
impact on concrete price.
47
3.3.4 Pionir in Jakarta Area
a) Pionir Kasablanka Plant
Located on Jalan Kasablanka, Jakarta.
Figure 3.13 Pionir Kasablanka Plant Location Map & Condition
Mixing Type Wet

Sieve Shaker 1 unit
Glass scale 3 unit
Slump cone and stick 2 unit
Material Sources
Fly Ash Location: Suralaya
Coarse Aggregate Location: Rumpin/Purwakarta
Supplier: Tarabatu/MSS
Fine Aggregate Location: Belitung/Ketapang
Supplier: KTP, PAP

Project Year
Shimizu-Total, Jo Menara Astra 2014-present
Shimizu-Total, Jo MNC Media 2014-2015 (suspend)
48
Quality Notice
Figure 3.14 Condition of Stockpiles without Appropriate Separation
1 No separation between Provide the wall separation
coarse aggregate stock pile. between material stockpiles.
o Mixing Design Issues
Figure 3.15 Pionir Mix Design Containing Manufacture Sand
Based on Shimizu institute test result, water absorptions of manufactured sand

are above 4%, which is out of SC JKT standard requirements. Mixing around 30%-
40% M. Sand in fine aggregate composition may harm the concrete, especially on
concrete resistant of shrinkage cracks.
1 Bad Characteristic of M. sand, Revised the mix design not to
water absorption above 4%. use M. sand
Mix design containing 30%-
40% of M. sand in fine
aggregate composition.
49
o Fly Ash Material Issues
Figure 3.16 Microscopic Image of Fly Ash Material Taken in Pionir Kasablanka Plant
Unstable condition of fly ash material will affect concrete quality and workability,
as explained in below table.
1 Unstable condition of fly ash, Avoid using fly ash in concrete
particle shape was flaky mix design due to unstable
instead of round. Sediment quality.
test results are beyond If there is no other option, do
tolerance. (see section 6.2-C simple fly ash sediment check
Fly Ash) on trial mix time to ensure its
performance in relation to
concrete workability and slump
loss. (see test method reference
on section 6.2-C Fly Ash)
b) Pionir Sudirman Plant

Located on Jalan Hasyim Azhari, Jakarta.
Figure 3.17 Pionir Sudirman Plant Location Map & Condition
Mixing Type Wet
50
Sieve Shaker 1 unit
Glass scale 1 unit
Material Sources
Coarse Aggregate Location: Rumpin/Purwakarta
Supplier: Tarabatu/MSS
Fine Aggregate Location: Belitung/Ketapang
Supplier: KTP, PAP

Project Year
Shimizu-Total, Jo Menara Astra 2014 (not used anymore)
Shimizu-Total, Jo MNC Media 2014 (not used anymore)
Quality Notice
In general, quality notices are very similar to Kasablanka plant, from mix design to raw
material issued. However, for fly ash condition, Sudirman plant is the worst from all. It
is strictly suggested to not use this plant for fly ash concrete. Below is comparison of
microscopic images between fly ash taken on Sudirman plant with other plant.
Figure 3.18 Microscopic view of fly ash
51
3.3.5 Pionir Outside Jakarta Area
a) Pionir Karawang Plant
Figure 3.19 Pionir Karawang Plant Location Map & Condition
Number of Truck Mixer 18 unit
Mixing Type Dry system

Compressive Test Machine 2000kN 1 unit
Sieve Shaker -
Glass scale 3 unit
Organic test 1 set
Slump cone 12 unit
Material Sources
Supplier: MSS
Supplier: Sherindo

Project Year
Proctor & Gamble 2011
MIURA 2012
KAO KKD 2013
GTEKT 2013
Sharp 2013
Yamaha motor 2014
52
Quality Notice
Like Adhimix Dawuan Plant, this plant also get raw material from around
Purwakrta & Cimalaka area. The problems are also very similar. High water
absorption characteristic leads to concrete cracking in several projects done such
as P&G, Miura and KAO. Detail explanation regarding this issue will be elaborated
on next chapter.
b) Pionir Kudus Plant
Located on Jl. Lingkar Kaliwungu Km 6, Kudus, Jateng.
Figure 3.20 Pionir Kudus Plant Location Map & Condition
Mixing Type Wet

Sieve Shaker 1 unit
Glass scale 1 unit
Concrete Flexural Test 1 unit
Capping Tools 1 unit
Material Sources
Fly Ash Location: Tanjung Jati
Supplier:
Coarse Aggregate Location: Jepara
Supplier: Calvari
Fine Aggregate Location: Rembang, Sluke
Supplier:
53
Project Year
SAMI Jepara 2014 – 2015
Quality Notice
Figure 3.21 Bad Coarse Aggregate Grading & shapes; High Clay Content Sand
concrete shrinkage or even structural strength. As seen on the pictures above,
coarse aggregate appearance is not so good. Many rounded shapes found and the
size grading is bad. In addition, judging from the color, fine aggregate seems to
have intolerable silt/clay content. Below are some problems on raw material that
found in Pionir Kudus Plant.
1 Coarse Aggregate:
At the time of Shimizu Do washing on truck at the time
institute investigation to of delivery material to batching
plant, checking result for plant before unloading.
material finer than sieve
no.200 is more than 20%
2 Fine Aggregate:
Current usage of rembang The sand cannot be use to cast
sand, silt content is over 11% wide surface area of concrete
with water absorption more such as slab and wall.
than 4%
3.3.6 Karya Beton in Jakarta Area

a) Karya Beton Antasari Plant
Figure 3.22 Karya Beton Antasari Plant Location Map & Condition
54
Material Sources
Coarse Aggregate Location: Rumpin
Supplier: Sidomanik, Kusumo
Fine Aggregate Location: Bangka/Belitung
Supplier: PAP

Project Year
MRT Jakarta 2015
Quality Notice
o Moisture Content Adjustment
Karya Beton Antasari Plant using speedy to determined daily moisture content for
water adjustment. However, in calculating water adjustment, they directly use MC
from speedy test result. This is not a correct way. Understand that speedy test
method is used to measure total moisture content whereas free moisture content
are needed to do water adjustment. Instead of directly using MC from speedy test
result, it is required to deduct the measured value with material water absorption
to get free moisture content (FMC). Only after that, the value may use to do water
adjustment calculation. Please find below explanation.
*Speedy Test : Total Moisture Content
3.3.7 Karya Beton Outside Jakarta Area

a) Karya Beton Klari Plant
Located on JL.Klari Km 7 Sukaresmi Karawang.
Karya Beton Plant

Klari Location
Figure 3.23 Karya Beton Antasari Plant Location Map & Condition
55
Number of Truck Mixer 15 nos
Mixing Type Dry

Sieve Shaker 1 unit
Speedy Moisture Content 1 unit
Cylinder Mold 50 unit
Material Sources
Supplier: BCA
Supplier: PAP
Previous Shimizu Project Experience

Project Year
KAO Chemical Project 2015
Nissin MFG Project 2014
Quality Notice
Generally, there are no technical problems on concrete final product result from
Karya Beton Klari Plant. Raw materials used are considered acceptable. However, in
batching process, this batching plant still needs to improve. Below are some notes
regarding Karya Beton Klari Plant.
No Problems Actions
1 (Identical Karya Beton Conduct technical meeting with
problem) plant manager, assign Shimizu
Water adjustment using total PIC on batching plant to monitor
moisture (TMC) directly from the batching process.
speedy test result.
2 Traceability for batch record To write manually mixer truck
is bad, no mixer truck no. number in batching record.
written in batch record For further improvement,
batching plant shall provide a
system that is able to record
truck mixer number on batching
record.
56
3.3.8 Torsina Redikon in Jakarta Area
a) Torsina Pulogadung Plant
Located on Kawasan Industri Pulogadung, Jl Rawa Sumur IV Bl BB/9 A-B Kawasan Industri
Pulogadung, Jatinegara, Cakung.
Figure 3.24 Torsina Pulogadung Plant Location Map & Condition
Quality Notice
No recent projects done using this batching plant.
3.3.9 Torsina Redikon Outside Jakarta Area

a) Torsina Cibatu Plant
Figure 3.25 Torsina Cibatu Plant Location Map & Condition
Material Sources
Coarse Aggregate Location: Cibogo
Supplier: -
Supplier: -

Project Year
SUAI 2011
SUAI Extension 2015
57
Quality Notice
o Raw Materials
Similar with other batching plant located in west java area, the most critical
problem is coming from raw material quality. High water absorption for both fine
and coarse aggregates may harmful to concrete, especially on its resistant to
shrinkage cracks. Fine aggregates water absorptions are reaching above 4% and
coarse aggregates above 6%. Beside water absorption issue, coarse aggregate
specific gravity also have some kind of problems for its value only 2,3 on dry
condition which below our standard (min. 2,5 on dry condition). Consider to find
other material sources for future projects to prevent previous cracking problem.
o Batching Process
Note that Cibatu plant is a small supporting plant with no proper batching
process. Batching system is manual, no batching records are provided. For
material weighing before loading, this plant only provided one bins for fine and
coarse aggregate with manual control. It is really necessary to put a PIC of
concrete from Shimizu to supervise batching process in this plant.
Figure 3.26 Loader put in aggregates into bin, weight is manually control on the sign board (circle marked)
b) Torsina Kalijati Plant
Figure 3.27 Torsina Kalijati Plant Location Map & Condition
58
Material Sources
Coarse Aggregate Location: Cibogo
Supplier: -
Supplier: -

No Shimizu projects done using this batching plant.
Quality Notice
Similar with other batching plant located in west java area, the most critical problem
is coming from raw material quality. High water absorption for fine aggregates, which
reach above 6%, may be harmful to concrete, especially on its resistant to shrinkage
cracks.
Batching process is better than Cibatu plant. Semi-Computerized system already
applied.
3.3.10 SCG-Jayamix in Jakarta Area

a) SCG-Jayamix Kebon Nanas Plant
Located on Jalan Kebon Nanas No. 71, DKI Jakarta.
Figure 3.28 SCG-Jayamix Kebon Nanas Plant Location Map & Condition
Batching Plant Area 12,000m2
Mixing Type Dry
59
Sieve Shaker 1 unit
Oven dry 1 unit
Slump cone and stick 8 set
Digital thermometer 2 unit
Material Sources
Cement Location: …
Supplier: Gresik, Jawa
Supplier: …
Supplier: Kusumo, Pion
Supplier: PAP

Project Year
Pakubuwono Residences 2003
MRT Jakarta 2015
Quality Notice
Generally, there are no technical problems on concrete final product result from SCG-
Jayamix Kebon Nanas Plant. Raw materials used are considered acceptable. Batching
process and facilities are also in an acceptable condition.
b) SCG-Jayamix Jelambar Plant

Located on Jalan Daan Mogot No. 118 Jatinegara , DKI Jakarta.
Figure 3.29 SCG-Jayamix Jelambar Plant Location Map & Condition
60
Mixing Type Dry

Moisture test-frying 1 set
Glass scale 3 unit
Balance 50 Kg 1 unit
Material Sources
Cement Location:
Supplier:
Supplier: Kusumo, Pion
Supplier: PAP

Project Year
TOTO Office Building 2015
MRT Jakarta 2015
Quality Notice
Generally, there is no problem in material selection. However, Toto project has suffer
early setting of concrete from this batching plant. When the designated 8 hours
setting time concrete was ordered for bore pile casting, it already began to set on the
3rd hour. Based on investigation results, this problem is coming from inappropriate
amount of admixture added while mixing concrete.
The scale of admixture dispenser is not accurate, so addition of admixture is not
accurate to mix design. After it was observed, they did the calibration together with
admixture’s company. Currently, the problem is solved. If future project have any
intention to use this batching plant, it is compulsory to crosscheck all the batching
facilities condition and calibration.
61
3.3.12 SCG-Jayamix Outside Jakarta Area
a) Jayamix Kudus
Located on Jalan Lingkar selatan, Kudus, West java.
Figure 3.30 SCG-Jayamix Dawuan Plant Location Map & Condition
Material Storage Area 1,500 m2
Production Capacity 21-28 m3/hour
Mixing Type Dry
Mixer Batch Capacity 3.5 m3/batch

Compressive Test Machine -
Moisture test-volumetric 1 set
Glass scale 3 unit
Balance 50 Kg 1 unit
Material Sources
Cement Location:
Fly Ash Location: Tanjung Jati
Supplier:
Coarse Aggregate Location: Jepara
Supplier: Calvary
Fine Aggregate Location: Rembang, Sluke, Boyolali
Supplier:

Project Year
SAMI Jepara 2014-2015
Quality Notice
Similar to Pionir Kudus plant which located just in the neighborhood of Jayamix
Kudus, main problems are in raw material quality. Both coarse and fine aggregate
cannot fulfil SC JKT bottom line requirement for slab crack prevention. Especially
sand, specific gravity is very low.
62
4 CONCRETE DESIGN
63
4.1 BOTTOM LINE REQUIREMENT
No. Items Requirements
1 Water Cement Ratio General < 65%
Around 28 MPa ~ 41%
Around 35 MPa ~ 48%
Around 42 MPa ~ 57%
2 Cement Content Min. 300 kg/m3
3 Water Content Max. 185 kg/m3
4 Sand Aggregate Ratio 45±3 %
5 Fine Aggregate No Manufactured sand
6 Coarse Aggregate Max. Size 25 mm
7 Admixture Designated admixture and setting time
shall be clearly mentioned
4.2 BASIC OF MIX DESIGN
4.2.1 Key Items on Mix Design

In designing concrete mixture, one must understand the key points that will affect the
concrete strength, workability and durability. Each of ingredients and composition
contributes particular properties in concrete. Below are some key items on mixing design.
a) Water-Cement Ratio
Water-cement ratio and strength relationship is usually determined from established
relationship based on historical data and can be considered the single most significant
factor or determinant of concrete strength. Below is the graph of water-cement ratio
relation with strength from SNI 03-2834-2000 (Tata Cara Pembuatan Rencana Campuran
Beton Normal) that used for mix design purposes.
Figure 4.1 graph of water-cement ratio relation with strength from SNI 03-2834-2000
It is often then followed by trial mixes (initial test) carried out at concrete batching plant
to verify its performance conformity to specified requirements. Judgment of trial mix
shall be compared with Fcr instead of Fc to confirm the required over-design factor.
64
b) Aggregate Properties
There are two characteristic of aggregates have an important influence on the mix
proportions of concrete mixture because they affect the workability of the fresh
concrete. They are:
Particle size distribution (grading)
Nature of the aggregates (particle shape, surface texture, porosity)
To determine the above important factors of aggregates, below consideration shall be
counted:
The choice of the maximum size of aggregate is governed by the size, shape of the
reinforced concrete element, thickness of its section, the designed cover to
reinforcement and reinforcement spacing.
The choice of aggregate and its maximum size is also governed by the availability of
the choice aggregate material and its cost.
The uniformity of the grading of the aggregates is an important feature in the
process of designing concrete compositions. Different grading categories are
specified for coarse and fine aggregates.
c) Consistence & Water Content
This is one essential property of concrete when designing a concrete composition. Before
proceeding to design the mix proportions, the required consistence type and class must
be decided. Though some text books or the ACI 211.1 proposes suitable levels of slump
for different types of building structures construction, the most suitable consistence type
and class is best determined by the method of placing and expected difficulty of the
placement.
When the consistence type and class has been chosen, the first step now is to determine
the amount of mixing water required. It is important to note that different cement type
may require different levels of mixing water for a given consistence class and cement
content. PFA for example, do not require as much mixing water as Portland cement at
constant cement content.
d) Cement Type
The type of cementitious material or combinations is usually decided based on
specifications by the specifier. Further specifications relating to this may include any
minimum and or maximum cement content and maximum allowable water/cement ratio.
These parameters are basically required for the concrete composition to meet the
specified durability requirements. The objective is to arrive at cement content and mix
composition that is economical and yet easily producible to meet the desired
consistence, strength and other specified properties.
It is also important to note that different types of cement will have different effect on the
total heat of hydration of the concrete. Hence, when placing large quantities of concrete,
such as for mass concreting, in large pours in hot (especially tropical) weather it is
imperative to consider using a suitable cementitious material that will result in reduced
rate of hydration and thus reduced heat of hydration of the cement.
e) Admixture
Admixtures are basically classified into the following:
65
Water reducers (plasticizers) – retarding and non-retarding
High range water reducers (superplasticizers) – retarding and non-retarding
Accelerators – chloride based and non-chloride based
Air entraining agents
Waterproofing
Pumping aids
Shrinkage compensating or reducing
Where the concrete will contain embedded steel reinforcement, chloride based
admixtures are not allowed. When using a combination of more than one admixture of
similar or dissimilar brands, the compatibility of the combination must be checked by
seeking advice from the producer/supplier. The water contained in the admixture should
be considered as part of the mixing water content should the amount of admixture
contribute to the water/cement ratio by 0.01 and more.
4.2.2 Sequence of Mixing Design

To design a concrete mixing, particular steps of determination are required. Below are the
summaries of sequence in determining concrete mixing.
Stage 1
Deals with determining the water/cement ratio for the required or specified target mean
strength from an established water/cement ratio-compressive strength relationship.
Stage 2
Determining the free water content from a table based on known aggregate type and
slump range.
Stage 3
Using the values obtained in stages 1 and 2, the cement content can be derived.
Stage 4
To determine the total aggregate content using density of fully compacted concrete
derived from a table using the free water content and assumed combined aggregate
specific gravity under SSD (saturated surface dry) condition.
Stage 5
Calculating the fine and coarse aggregate proportions by first determining the fine
aggregate proportion using known water/cement ratio and value of percentage passing
600 micron sieve
4.2.3 Required Over-Design Factors

Statistical data shown concrete cylinder strengths vary by as much as ± 20% if the same
technician makes and breaks all of the cylinders. If in another cases, several different
technicians make and break the cylinders, the strength can vary by as much as ± 30%.
66
Figure 4.2 Graph of overdesign factor
Due to this condition, if the average cylinder strength is equal to the design strength, then
half of all the tested cylinders will fail to meet the strength requirements. These pours will be
rejected and replaced.
To overcome the variation on actual mixing concrete, some overdesign factors are required
to ensure the designated concrete could meet specified requirements. Statistically, based on
the above illustration, average strength shall be greater than design strength (f’c). By
increasing the required average strength (f’cr), the number of fail data objective to design
strength (f’c) may be reduced.
Average Required Strength is defined based on data variations of past concreting. The more
the variation (or deviation), the higher average is required. Based on ACI 318, f’cr shall be
defined as below listed:
67
Required average compressive strength when data are available to
establish a standard deviation
Specified compressive Required average
strength f'c, compressive strength f'cr,
N/mm2 N/mm2
use the larger value computed
from EQ (5-1) or (5-2)
f'c < 35
f'cr = f'c + 1.34S (5-1)
f'cr = f'c + 2.33S - 3.45 (5-2)
from EQ (5-1) and (5-3)
f'c = over 35
f'cr = f'c + 1.34S (5-1)
f'cr = 0.90 f'c + 2.33S (5-3)
Required average compressive strength when data are not

available to establish a standard deviation
Specified compressive strength Required average compressive

f'c, N/mm2 strength f'cr, N/mm2
Less than 21 f'c + 7.0
21 to 35 f'c + 8.5
over 35 1.1 f'c + 5.0
68
4.3 PREVIOUS PROJECT REFERENCES
4.3.1 MIX DESIGN OF NORMAL STRENGTH CONCRETE

Unit Weight of Concrete (kg/m3)
Slump
Grade Project Plant W/C(%) S/A(%) Natural M- Total Coarse Ad (Cx%)
(cm) OPC Water Total
Sand sand Sand Agg. S.P Retarder dosage
ADHIMIX
50.0% 41.5% 12±2 344 172 752 0 752 1060 1030 0 0.35 2328
MIURA (Dawuan)
fc 24
(Karawang) KARYA B.
53.9% 46.0% 12±2 310 167 892 0 892 1028 900 0 0.34 2397
(Karawang)
ADHIMIX
48.0% 36.6% 12±2 358 172 686 0 686 1186 0 1070 0.00 2402
USUI (Cibitung)
Fc 24
(Cikarang) Jaya Mix
45.1% 41.8% 12±2 388 175 610 150 760 1060 820 1940 0.25 2383
(Cikarang)
TRHI
fc 24 KARYA B. 53.1% 45.0% 12±2 318 169 830 0 830 1038 900 0 0.33 2355
(Cikarang)
ADHIMIX
fc 24 HPPM 55.9% 42.0% 12±2 315 176 767 0 767 1059 0 950 0.00 2317
(Dawuan)
ADHIMIX
fc 24 55.9% 42.0% 12±2 315 176 767 0 767 1059 0 950 0.00 2317
NISSAN (Dawuan)
(Cikampek) Jaya Mix
fc 24 51.5% 45.4% 12±2 340 175 830 0 830 1000 1700 1440 0.59 2345
(Dawuan)
ADHIMIX
fc 24 51.0% 45.5% 12±2 343 175 850 0 850 1013 0 950 0.00 2381
SUGITY (Cibitung)
(Cibitung) PIONIR
fc 24 54.0% 59.38% 12±2 324 175 720 230 950 880 0 810 0.00 2329
(Cikarang)
69
Slump
ADHIMIX
fc 24 55.9% 42.0% 12±2 315 176 767 0 767 1059 0 950 0.00 2317
(Cibitung)
SHARP Jaya Mix

fc 24 51.5% 43.5% 12±2 340 175 800 0 800 1040 1700 1152 0.59 2355
(Karawang) (Cikarang)
PIONIR
fc 24 52.0% 57.2% 12±2 344 179 690 220 910 900 0 850 0.00 2333
(Karawang)
ADHIMIX
fc 24 55.9% 42.0% 12±2 315 176 767 0 767 1059 0 950 0.00 2317
(Dawuan)
G-TEKT Jaya Mix

fc 24 51.5% 45.4% 12±2 340 175 830 830 1000 1700 1440 0.59 2345
(Cikampek) (Dawuan)
PIONIR
fc 24 54.0% 52.4% 12±2 324 175 780 90 870 880 0 950 0.00 2249
(Karawang)
REDIKON
fc 24 50.0% 62.7% 12±2 340 170 440.3 440.3 880.6 961.47 1221 0 0.42 2352.07
(Karawang)
PIONIR
fc 24 49.3% 51.0% 12±2 345 170 810 90 900 950 1949 0 0.67 2365
KAO (Karawang)
(Karawang) ADHIMIX
fc 24 50.0% 47.5% 12±2 340 170 866 0 866 974 2305 0 0.80 2350
(Dawuan)
KARYA B.
fc 24 46.0% 45.0% 12±2 348 160 827 0 827 1035 1246 0 0.42 2370
(Karawang)
TSUCHIYA ADHIMIX
fc 24 55.9% 45.7% 12±2 315 176 862 0 862 1021 940 0 0.35 2374
(Cibitung) (cikarang)
70
Slump
JAYAMIX
fc 24 51.5% 44.1% 12±2 340 175 820 0 820 1040 1430 800 0.50 2375
NT (cikarang)
(Cikarang) ADHIMIX
fc 24 55.9% 43.2% 12±2 315 176 812 0 812 1062 940 0 0.35 2365
(cikarang)
JAYAMIX
fc 24 SAMI 55.9% 52.2% 12±2 322 180 980 0 980 900 1230 0.30% 0.45 2382
(JEPARA)
JEPARA
(Jepara) PIONIR
fc 24 49.7% 48.8% 12±2 342 170 911 0 911 966 1450 0.30% 0.50 2389
(JEPARA)
PIONIR
fc 24 53.6% 44.5% 12±2 308 165 830 0 830 1050 1220 360 0.47 2353
TOYORIKO (Cikarang)
(Cibitung) ADHIMIX
fc 24 55.9% 44.1% 12±2 315 176 818 0 818 1062 940 0 0.35 2371
(cikarang)
KARYA
fc 24 BETON 46.0% 46.6% 12±2 313 144 884 0 884 1055 4610 0 1.74 2396
KINC (Cikarang)
(Cikarang)
PIONIR
fc 24 49.3% 49.3% 12±2 345 170 900 0 900 950 2400 0 0.82 2365
(Cikarang)
JFE(Cibitun INDOCEMEN
fc 24 55.0% 43.7% 12±2 340 187 660 224 884 898 4610 0 1.60 2309
g) T
ADHIMIX
fc 24 55.9% 55.6% 12±2 315 176 1022 0 1022 837 950 0 0.36 2350
YAZAKI (Dawuan)
(Subang) JAYAMIX
fc 24 51.5% 44.4% 12±2 340 175 800 0 800 1040 2400 0 0.83 2355
(SUBANG)
71
Slump
G TEKT ADHIMIX
fc 24 55.9% 55.6% 12±2 315 176 1022 0 1022 837 950 0 0.36 2350
(Cikampek) (Dawuan)
KARYA
KAO- VD9
fc 24 BETON 52.2% 46.1% 12±2 324 169 859 0 859 1031 1600 0 0.58 2383
(Karawang)
(Karawang)
ADHIMIX
fc 24 (Dawuan)type 48.0% 49.1% 12±2 342 164 906 0 906 959 1880 0 0.65 2371
B
ADHIMIX
B.BRAUN
fc 24 (Dawuan)type 40.0% 49.1% 12±2 375 150 910 0 910 964 2060 1130 0.65 2399
(Cikampek)
C
KARYA
fc 24 BETON 77.8% 51.0% 12±2 180 140 1051 0 1051 1032 400 0 0.26 2403
(Klari)type A
KARYA
fc 24 BETON 45.9% 46.1% 12±2 340 156 867 0 867 1040 1000 0 0.35 2403
B.BRAUN (Klari)type B
(Cikampek) KARYA
fc 24 BETON 40.0% 45.2% 12±2 375 150 844 0 844 1051 1100 0 0.35 2420
(Klari)type C
ADHIMIX
fc 24 55.9% 43.2% 12±2 315 176 788 0 788 1076 950 0 0.36 2355
(Dawuan)
HANYA
(Deltamas) KARYA
fc 24 BETON 52.0% 47.4% 12±2 300 156 908 0 908 1033 890 0 0.35 2397
(Delta Mas)
ADHIMIX
fc 24 55.9% 44.1% 12±2 315 176 794 0 794 1048 950 0 0.36 2333
MEIRA (Dawuan)
KARYA
fc 24 (Karawang) BETON 52.0% 47.4% 12±2 300 156 908 0 908 1033 890 0 0.35 2397
(Badami)
72
4.3.1 MIX DESIGN OF HIGH STRENGTH CONCRETE
Slump
Grade Project Plant W/C(%) S/a(%) Natural M- Total Coarse Ad (Cx%)
ADHIMIX
fc 35 (Lenteng 44.6% 18.8% 12±2 361 161 742 0 742 1122 1080 0 0.34 2386
Agung)
ADHIMIX
fc 35 (Lenteng 44.6% 40.0% 18±2 372 166 733 0 733 1109 1120 0 0.35 2380
Agung)
ADHIMIX
fc 35 (Lenteng 44.5% 40.0% 16±2 384 171 724 0 724 1095 1150 0 0.34 2374
Agung)
ADHIMIX
fc 35 (Lenteng 44.6% 40.0% 18±2 395 176 715 0 715 1081 1180 0 0.34 2367
Agung)
ADHIMIX
fc 40 (Lenteng 40.6% 40.0% 14±2 421 171 712 0 712 1077 1260 0 0.34 2381
Agung)
ADHIMIX
SIMA
fc 40 (Lenteng 40.6% 39.7% 14±2 433 176 703 0 1063 1077 1300 0 0.35 2389
TUPANG
Agung)
ADHIMIX
fc 45 (Lenteng 36.8% 40.0% 12±2 462 170 699 0 699 1057 1390 0 0.35 2388
Agung)
ADHIMIX
fc 45 (Lenteng 36.8% 40.0% 14±2 476 175 689 0 689 1042 1430 0 0.35 2382
Agung)
ADHIMIX
fc 45 (Lenteng 36.8% 40.0% 16±2 489 180 680 0 680 1027 1470 0 0.35 2376
Agung)
ADHIMIX
fc 50 (Lenteng 33.3% 40.0% 12±2 522 174 674 0 674 1020 1570 0 0.35 2390
Agung)
ADHIMIX
fc 50 (Lenteng 33.3% 40.0% 16±2 537 179 664 0 664 1004 1610 0 0.34 2384
Agung)
73
Slump
ADHIMIX
fc 50 (Lenteng 33.3% 40.0% 16±2 553 184 654 0 654 988 1660 0 0.35 2379
Agung)
PIONIR
fc 40 35.0% 38.8% 12±2 471 165 400 260 660 1040 2500 930 0.63 2336
(Antasari)
PIONIR
fc 45 31.9% 36.7% 12±2 518 165 370 240 610 1050 2500 1030 0.57 2343
(Antasari)
PIONIR
fc 50 30.3% 36.4% 12±2 545 165 450 150 600 1050 0.85 0.00 2360
SIMA (Antasari)
TUPANG
PIONIR
fc 35 36.6% 39.4% 14±2 465 170 400 270 670 1030 2250 0.92 0.57 2335
(Antasari)
PIONIR
fc 40 35.3% 38.5% 14±2 482 170 390 260 650 1040 2750 0.96 0.67 2342
(Antasari)
PIONIR
fc 45 69.4% 36.7% 14±2 533 370 370 240 610 1050 2750 1.06 0.61 2563
(Antasari)
PIONIR
fc 50 29.4% 35.6% 14±2 562 165 440 140 580 1050 0.87 0.00 2357
(Antasari)
ADHIMIX
fc 40 (Tanah 41.3% 40.0% 15±2 431 178 673 0 673 997 650 0.18 2279
Abang)
ASTRA ADHIMIX
fc 55 (Sudirman, (Tanah 16.2% 40.0% 18±2 517 84 690 0 690 1023 780 0.18 2314
JKT) Abang)
PIONIR
fc 40 35.1% 50.0% 15±2 485 170 670 0 670 930 4570 0.87 1.11 2255
(Kasablanka)
74
Slump
PIONIR
fc 40 33.5% 50.0% 15±2 538 180 530 0 530 920 3160 0.87 0.69 2168
(Kasablanka)
ASTRA
PIONIR
fc 55 (Sudirma 103.1% 50.0% 15±2,5 640 660 680 0 680 940 4.25 0.87 0.00 2920
(Kasablanka)
n, JKT)
PIONIR
fc 55 103.0% 50.0% 18±2,5 165 170 650 0 650 940 4.25 0.87 0.00 1925
(Kasablanka)
ADHIMIX
43.8% 50.0% 16±2 486 213 626 0 626 1010 0 1.22 0.00 2335
(Tanah Abang)
fc 40 ADHIMIX
43.8% 50.0% 18±2 498 218 618 0 618 996 0 1.25 0.00 2330
NFA- (Tanah Abang)
nonflya PIONIR
sh 32.3% 50.0% 16±2 511 165 700 0 700 1020 0 1.17 0.21 2396
(Kasablanka)
MNC PIONIR
31.5% 50.0% 18±2 524 165 700 0 700 1010 1200 0.24 2399
(Kebon (Kasablanka)
Sirih, ADHIMIX
JKT) 32.5% 80.4% 16±2 517 168 691 0 691 1024 5690 0.78 1.17 2400
(Tanah Abang)
ADHIMIX
32.5% 80.4% 18±2 517 168 690 0 690 1023 6200 0.78 1.28 2398
fc 50 (Tanah Abang)
NFA PIONIR
27.0% 80.5% 16±2 593 160 660 0 660 1010 5560 1.16 1.00 2423
(Kasablanka)
PIONIR
26.4% 50.0% 18±2 605 160 650 0 650 1000 5710 1.18 1.01 2415
(Kasablanka)
75
Slump
ADHIMIX
MNC 30.7% 50.0% 16±2 564 173 686 0 686 976 6200 0.85 1.17 2399
fc 55 (Tanah ABang)
(Kebon
NFA ADHIMIX
Sirih, JKT) 30.7% 50.0% 18±2 564 173 685 0 685 975 6700 0.85 1.27 2397
(Tanah Abang)
ADHIMIX
fc 30 (Taman 53.1% 43.8% 15±2 341 181 767 0 767 979 800 0 0.28 2268
Anggrek)
ADHIMIX
fc 30 (Taman 49.4% 44.8% 15±2 360 178 815 0 815 999 720 0 0.24 2352
Anggrek)
ADHIMIX
fc 37 (Taman 44.9% 42.3% 15±2 412 185 703 0 703 957 970 0 0.28 2257
TOTO Anggrek)
(Slipi, JKT) ADHIMIX
fc 37 (Taman 42.2% 43.7% 15±2 438 185 748 0 748 961 880 0 0.24 2332
Anggrek)
ADHIMIX
fc 30 (Taman 54.4% 39.3% 20±2 344 187 681 0 681 1047 860 0 0.30 2259
Anggrek)
ADHIMIX
fc 30 (Taman 53.8% 44.0% 20±2 344 185 765 0 765 972 1630 0 0.56 2266
Anggrek)
76
5 CONCRETE CONTROL FOR SITE CASTING
77
5.1 BOTTOM LINE REQUIREMENT OF CONCRETE SITE CONTROL & MONITORING
No Time Check Items Requirement Remarks
DELIVERY TICKET CHECK

Supplier To be mentioned on delivery ticket
Batching Plant To be mentioned on delivery ticket
Location
Delivery Ticket To be mentioned on delivery ticket
Number
Date To be mentioned on delivery ticket
Mixer truck no. To be mentioned on delivery ticket Supplier shall
attach batch
Project Information To be mentioned on delivery ticket
detail on
Concrete grade To be mentioned on delivery ticket
delivery time.
Cement Type Comply with mix design
Max. Aggregate Size To be mentioned on delivery ticket
Additional Ingredients To be mentioned on delivery ticket
Volume To be mentioned on delivery ticket
Slump design To be mentioned on delivery ticket
DELIVERY INSPECTION
Batch time To be mentioned on delivery ticket

Departure time To be mentioned on delivery ticket
1 every truck mixer
TEMPERATURE CHECK Max. 38oC;
Complete temp. measurement
within 5 minutes after obtaining the
samples;
Every truck mixer
SAMPLING
Procedure The elapsed time shall not be exceed
15min after obtain the first & final
portions of sample
Cylinder Numbers 2 samples min for each purpose of
testing. (i.e. 2 for 7 days, 2 for 28
days, 2 for spare, etc.) for one set of
samples
Representative A set of samples represent 115m3
Amount volume or 465m2 surface, taken
from 1 truck mixer
Sample Code Not allowed to do direct scratch on
top surface
Sticker put at top at first
78
SPECIMEN CURING
Pond No leakage, all specimen shall be
fully cured under water
2 CURING Location Free from vibration and from direct
sun light
Disposal of Molding After 24H
Temperature Ambiance
COMPRESSIVE
Independent 3rd party laboratory for

TEST
LABORATORY SELECTION
3 28 days
ACTUAL
Pouring Area To be clearly recorded
Truck Number To be clearly recorded

Concrete Grade To be clearly recorded
Slump Design To be clearly recorded

Volume To be clearly recorded
Sample Code To be clearly recorded
Casting Date To be clearly recorded
Time
Batch To be clearly recorded
Departure To be clearly recorded
Arrival To be clearly recorded
Un-Loading To be clearly recorded;
MONITORING
Not more than designated initial setting

4 time
Finish To be clearly recorded
SUMMARY

Compressive Strength
Test Result
7 days Around 65% of design strength
28 days 100% of design strength
Others (as required)
79
5.2 SC JKT CONSTRUCTION & QUALITY CONTROL SHEET
Assist. SPV in Surveyor
Division Project name Revision 2 JKT Office PM Q.A. Staff doing inspection
Quality & Construction Control Sheet 䠄Construction) PM Charge in Charge
14-01
Concrete Work
Indonesia xxxx 3-Mar-15
Checking Method Person in charge Record Consultant/ Preservat

Control items Quality target (Acceptance criteria) Check (Inspection)
Time Object Method SC Sub-Con name designer confirm ion
1 Selection of Concrete New plant for Shimizu, plant facilities, materials, and
Batching Plan quality control system shall be checked.
To use batching plant with wet mix system
Aggregate stock yards are covered with roof,
separated by partitions and equipped with
sprinkler to avoid dry up.
Temperature and moisture in laboratory are
controlled, and curing water temperature is
controlled Check
Supply capacity (m3/h) shall be good enough point on
ready
Past result of coefficient of variation (%䠲) and
mixed
Standard Deviation(S) for concrete strength are Before 1st Plan visit
o o concrete o
clearly recorded and confirmed it is sufficient. placement Visual
plan (
䠄V=S/Mixing strength 䠢㽢100,㻌 V shall be below
refer to
10% on Typical F䠅
attached
f'cr {(Required Average strength)= fc'+1,34S (when
) photo.
test of same fc' has been carried out more than 30
times) or f'cr= fc'+8,5N (when fc' =21N or more
Planning
with No Test has been carried out)} has been
confirmed and Design mix has been fulfilled on
these formula.
䞉To check test method of material's moisture
content, shall be use oven dry method, minimum 2
times/day or every after heavy rain
2 Selection of Testing The testing laboratory shall be reliable independent that
Laboratories Shimizu makes the contract.
In case testing laboratory is other than the above, Shimizu Authorized
representative shall attend all tests and take photo Certificate
showing the max. gauge of all strength tests Before 1 Laboratory Work
st Visit o Experience o
placement Visual Method
Statemen of
testing
80
Record Consultant/ Preservat
Control items Quality target (Acceptance criteria) Checking Method Person in charge Check (Inspection)
name designer confirm ion
1 Mix Proportion Plan To confirm concrete supplier that The average
strength for the mix design should equal the specified
strength plus an allowance to account for variations in
materials; variations in methods of mixing,
transporting, and placing the concrete; and variations
in making, curing, and testing concrete cylinder Mix
specimens. proportion
Mix proportion plan together with Test data on course plan (Refer
Mix
aggregate, fine aggregate, cement, water, mixing Before to
Proportion o o o o
materials, admixture shall be checked and approved Trial Mix attached)T
Document
by the Designer est report
Content per unit volume of concrete shall be; on Trial
o Water; less than 185kg/m3, water must have Mix
impurities test result
o Cement; more than 300kg/m3
o Water-Cement Ratio shall be less than 65% (in
case of ordinary Portland cement)
Mix Proportion
o Concrete strength shall be confirmed by trial
After Trial 28d test
mixing and obtain approval by S/Designer
Mix result
Before
Sand-aggregate ratio shall be 45 ± 3% Trial Mix
2 Mixing Tolerance Tolerance for batching constituent to follow ASTM C 685,
as table below:
o Cement & fly ash: ±1% Right after Job mix
o Water: ±1% mixing design
o Aggregate: ±2%
o Admixture: ±3%
1 Concrete Placement Participant study and planning for concreting , as
Meeting Volume, Placing time and period, Enough manpower,
Proper organization, Enough number of
Before Each
Vibrator/Equipment etc. Check o Concrete Plan o
Placing Operation
To review previous concreting result and feedback
time to time
In case several concrete plants to be used, placed area

by each plants shall be recorded on drawing clearly. In
case adjacent area to be placed by different plant on Before C Each
Visual o
same day, area to be separated to avoid mixing by placing Operation
wire mesh etc.
Inspection Before Placement

2 Check Up at Remove laitance with wire brushes. No chip of wood and
Before C
Construction Joint garbage Visual o Photo o
placing
Condition
81
3 Treatment for Horizontal concrete joint shall be free from laitance using
Before C
Horizontal Concrete wire brush, high pressure water jet, etc. Visual o
Placing
Joint for Mat Slab
4 Dampness Condition of Sheeting board is wet enough Before C
Visual o o
Sheeting Board Placing
5 Stay Free Water on C- No free water exist
Before C
Placement
Joint In The Form of Visual o Photo o
Placing
Inspection Before
Column/Wall
6 Clean in and on The No rubbish or waste materials in and on form Before C
Visual o o
Form Placing
1 Visual Inspection of No abnormality in color, shine and plasticity in particular.
Ready Mix Concrete No segregation.
Delivery Check o Photo o
Sample of Segregation in Concrete
2 Collection of Test Minimum 6 cylinders (from same truck) must be

Samples collected for each lot each 150yd3(115 m3) and/or
5000ft2(465 m2) wall/floor, for strength test as below:
o 2 cylinders for 7 days
o 2 cylinders for 28days
o 2 cylinders for spare
7days test required based on structure designer's
requirement. Other than above, 2nos spear shall be Once/section,
provided for emergency testing at a time of every day and
collection. Concret
once/115 m3, *Based on concrete
Inspection Upon Delivery

In case several concrete plants to be used on same day, e quality
once/500m2 o o Quality Record Table
the above test pieces shall be collected on each plant. record
wall/floor or arranged separately.
Not to use scratch to identify cylinder sample to list
according to
damage the surface of concrete cylinder. specifications.
Recommended to use sticker (see sample picture
below).
Sample of top of cylinder sample, marked with sticker
82
3 Slump Test Slump(cm) 8 to 18㻌㼼2.5䠄over 18 ±1.5䠅
Check proper slump test method; fill in cone in 3 layers,
each layer hit in 25 times.
To check concrete segregation as picture below:
Every truck
Visual Photo
mixer
4 Salinity in Concrete Salinity shall be less than 0,3 kg/m3. 1 Time/day

For those where underground soil contains rock salt or in cace sea
sulfide, consult with technical department sand : 1 Photo
time/150m
3
5 In Case of Test Failure Reject.
Inspection Upon Delivery

In case using super plasticizers, shall be approved by
structure designer and shall follow the designer’s o o
instruction (do not add water to concrete at site).
6 Curing of Test Pieces Shall be stored until removal of form under shades and At each
airy place without any vibration. collection
o
of test
pieces
7 Method statement of The above mentioned inspection method statement shall Inspection
Before
Acceptance Inspection be approved by structure designer. Check o Method o o
Placing
Statement
1 Time for Shipment of Temperature over 25Ԩ, within 90 mins. Less 25Ԩ, within
Ready-Mix Concrete Up 120 mins. Each Measure
Placing o
to Pouring Place at Site Section ment
All seasons in Indonesia :

When the concrete retarder is not used: Max. 60 mins. o
When the concrete retarder is used: Max. 90 mins.
Each
Placing Visual Photo o
Part
Concrete Placement
83
2 Time Distance for In case to use a retarder agent, It shall get approval from
Overlap Placing the designer. Before
Each area Check o o
Concrete Placing
3 Method of Vibrator Concrete vibrator shall be used during concrete placing

Operation and insertion distance to be around 50 cm as reference,
Placing Each Part Visual Photo o
Vibrating time: Approx. 10 seconds/one time. Insert depth

is about 20cm into concrete placed initially .
4 Knocking From while Knock predetermined number of times. No irregularity on
Placing sheathing board shall be allowed. o
5 Tamping for Slab All slab’s surface to be tamped more than one time after
initial concrete placing w/ leveling has been completed
and then refinish concrete surface with wooden trowel.
Concrete Placement
Each Part Visual Photo o
6 Slab Surface Precision SCJKT standard are as follows:

with Monolith (Steel o To receive waterproof membrane : from standard
o
Trowel) Finish level -5mm to +10mm㻌
o Floor for factory/Warehouse : from standard level -
Measure
5mm to +5mm 10²/Place Photo o
ment
o To receive flooring materials for office : from
standard level -5mm to +7mm
o Area beside where skirting to be installed : less than
3mm within 2m long
7 Sloop at Roof Slab Roof slab shall be properly sloped, and basically does not
allow a bleeding area. However, bleeding area of less than Measure
1 m2 /place at each may be acceptable with they are not 10²/Place Photo o
ment
become water ponding.
84
8 Situation after At columns and walls, Horizontal construction joint
Placement shall be troweled /tamped for level and straight
properly. It is recommended to place concrete slightly
After
higher than surrounding to prevent stagnant breezing Joint Visual
Placing
water.
For high column/wall, usage of pipe or hose are
compulsory to prevent segregation o
No leaked concrete paste on the floor underneath and
do not stained Starter re-bars by concrete paste. C
Concrete Placement
paste shall be move out by cloth when they are
Each Part Visual
stained.
In case Plastic initial crack has occurred, tamping to
concrete surface by trowel shall be carried out.
1 Curing of Slab and Wall More than seven day's curing w/water after placement
and for continuously keeps in wet state.
Each Wall and
Using curing compound is totally not recommended. Wet Visual Photo o
Placing floor face
curing is a much better way. However, if curing compound
is used, method of dosage control shall be established. o
Concrete strength has been reached more than 10
N/mm2. Curing can be terminate incase the part of
Curing
Compression test per each section
thickness of structure element is more than 18 cm.
2 Next Day Situation of Any form, reinforcement, scaffolding materials shall not
Concrete Slab be loaded on the slab After Slab
Visual Photo o
Placing surface
1 Slab surface accuracy SCJKT standard are as follows:

o To receive waterproof membrane : from standard
Level
level -5mm to +10mm㻌
inspection
o Floor for factory/Warehouse : from standard level -
After Corner & Measure record(
5mm to +5mm o
placing Center ment Working
o To receive flooring materials for office : from
drawing
standard level -5mm to +7mm o
note)
Area beside where skirting to be installed : less than 3mm
within 2m long
2 Slab thickness Slab thickness is not less than designed
Measure it at
confirmation
opening and
(measure by openings, a
plumbing hole
plumbing holes)
Placed concrete accuracy of outlook, external angle, and
horizontal joint and vertical joint are visually good. After Each Accuracy
Concrete Placing Inspection

Placing Section inspection
record
o o
3 Concrete placing (Working
accuracy Opening reveal precision balcony eaves is good drawing
Each Part Visual note)
Verticality of column/wall: less than 3/1000; alignment:
less than ±7mm
85
4 Cross section deficit on Cross section deficit rate by wall crack control joint shall
wall crack control be more than 20% of total wall thickness. Visual/M
joint/cross section No cross section deficit shall be applied to column, beam Each
Planning easurem o
deficit by glove and structure wall. Section
ent
5 Concrete surface Honeycomb: coarse aggregate does not crop out on *Based on’’Concrete
After Placing
condition after form the surface. Exterior Inspection Method’’
Remove Visual o Inspection
removed Cold joint: No cold joint is visible/exist. Wall Face arranged separately .
From Record
6 Concrete cracks Cracks to be less than 0.2mm is may carry out
following finishes without crack repairing.
o (Elastic spray paint, Mortar plastering, and Tile
fixing with mortar)
Concrete Placing Inspection

Before Exterior Measure
Cracks to be less than 0.06mm is for following finishes o o o
Finish wall face ment
o (Lythin and inelastic spray paint, exposed concrete,
Tile on direct fixing)
Less than 0.3mm is may be apply finishes without

Inner Measure
crack repairing
Wall ment
Suspended slab: subject to cracking look like a circle
along beams
Cantilever slab 䠖subject to cracking at along the slab
Curing
support beam
7 Location, size and shape Same as sleeve drawing
of penetration sleeve After Each Measure
Casting sleeve ment
1 Treatment for When deviating from SC standard is found, proper RC

honeycomb, cold joint treatment is required based on concrete remedial Structure
Before
and crack standards indicated on "RC structure clearance inspection Each Part Visual o Clearance o o
Finish
records". Subject to structure engineers approvals. Inspection
Treatment
Record
1 Compressive strength One test (average of specimen) result shall not be less
(acceptable concrete than 3,5N/mm2 of design strength.
*Base On Concrete
quality) In addition, average of three consecutive strength test Concrete
Regulated Attendin Compres Quality Record Table(
result is more than design strength. o Strenght o
timing g test sion test Strenght Test Record)
Average of concrete strength result shall be more than Test Table
arranged separately.
"Required average concrete strength"
"Rac’s" value is subject to Each plant own "S"
2 Compressive strength For beam and suspended slab, shall reach 100% of
(Prop removal time design strength
Concrete
decision use) For column & other structures without starter bar, to Regulated Compres
o Strenght o
Confirmation of Strength
reach 5N/mm2 Timing sion test
Test Table
For column & other structures without starter bar, to
reach 10N/mm2
86
Table 5.1 ACI REQUIRED AVERAGE CONCRETE STRENGTH
(CONCRETE STRENGTH FOR MIXING DESIGN)
Required average compressive strength when data are available to

establish a standard deviation
Specified compressive Required average

strength f'c, compressive strength f'cr,
N/mm2 N/mm2

from EQ (5-1) or (5-2)
f'c < 35
f'cr = f'c + 1.34S 5-1)
f'cr = f'c + 2.33S - 3.45 (5-2)
from EQ (5-1) and (5-3)
f'c = over 35
f'cr = f'c + 1.34S 5-1)
f'cr = 0.90 f'c + 2.33S 5-3)
Required average compressive strength when data are not

available to establish a standard deviation
Specified compressive strength Required average compressive
f'c, N/mm2 strength f'cr, N/mm2
Less than 21 f'c + 7.0
21 to 35 f'c + 8.5
over 35 1.1 f'c + 5.0
87
Table 5.2 ACI (SAMPLING NUMBER OF SPECIMEN FOR FREQUENCY OF TESTING)
Places Cast in Situ Columns / Walls / Beams /

Foundations Remarks
Concrete Piles Ground Slabs Suspended Slabs
7 Days
2 2 2 2 Field cure
For Information
28 Days
for Acceptance of 2 2 2 2 Lab. Cure
Concrete Strength
STRENGTH
v v v v
Spare for 2 2 2 2 Field cure
28 days
£ £ £
- 2 2 2 Field cure
Side Form
FORM
¯
REMOVAL
Bottom Form and - - - 2 Field cure
Shores
Number of Specimens per Test 6 8 8 10
No need tests when 28 days result is confirmed
v
acceptable.
No need sampling in case side form remain unremoved within 24
£
hours.
No need sampling in case bottom form and shores remain unremoved within
¯
28 days.
Minimum Number of Strength Test Per Day
² Once per day, nor less than,
² Once for each 150yd3(115m3) of concrete placed, nor less than,
² Once for each 5000ft2(465 m2) of surface area of slabs or walls placed.
88
5.3 JOB DESCRIPTION SUMMARY OF CONCRETE PIC
5.3.1 INITIAL STAGE

No Time Activity Description Record
1 Batching Plant
Checking
General Batching plant profile QC-Concrete-RCD-BP01 Pre-
Information Trial Mix
Facilities Checking on facilities condition QC-Concrete-RCD-BP04
Facilities Check Sheet
Raw Checking on raw material QC-Concrete-RCD-BP03 Raw
Material condition through test report Material Check Sheet
and actual check comparison QC-Concrete-RCD-BP03-A
(on plant testing sampling & Fine Aggregate Analysis
witness by SHIMZ) QC-Concrete-RCD-BP03-B
Coarse Aggregate Analysis
Before Trial Mix
Admixture Admixture supplier shall do trial QC-Concrete-RCD-BP01 Pre-

Dosage mixing to ensure the dosage and Trial Mix
Confirmation inform to SHIMZ
Material Test at To send Fine and Coarse Actual 3rd party test result
Independent aggregate for material analysis
Lab. (grading, FM, SG, etc.)
Mix Design
Check
W/C Ratio >65%
Water <185 lt/m3
Cement >300 kg/m3 QC-Concrete-RCD-BP01 Pre-
S/A Ratio 45±3% Trial Mix
Designated Clearly mention how many liter
Admixture admixture used
Designated Clearly mention how many
Setting Time hours setting time designated
2 Condition
Check
Conveyor Clean condition, no excess QC-Concrete-RCD-BP02 Trial
material Mix;
QC-Concrete-RCD-BP07
Batching Plant Check Photo
Trial Mix
Record
Truck Mixer No outstanding water inside QC-Concrete-RCD-BP02 Trial
Mix
Material Data Actual data for water QC-Concrete-RCD-BP02 Trial
adjustment: Fine agg. moisture Mix
content and water absorption
Mix Design To comply with requested QC-Concrete-RCD-BP06 Mix
Check concrete spec and grade Design Adjustment Sheet
89
2 Batch Check correction result after QC-Concrete-RCD-BP06 Mix
Adjustment water adjustment Design Adjustment Sheet
Check
Batching Check batching accuracy to QC-Concrete-RCD-BP02 Trial
Process meet the tolerance Mix
Trial Mix
Accuracy Check
Slump Lost & Monitor slump lost and QC-Concrete-RCD-BP02 Trial
Temperature temperature from fresh Mix;
concrete condition, after QC-Concrete-RCD-BP07
admixture addition until Batching Plant Check Photo
designated setting time Record
Salinity Check Actual result of salinity cannot QC-Concrete-RCD-BP02 Trial
be more than 0,3 kg/m3 Mix
Cylinder sample To provide cylinder sample in QC-Concrete-RCD-BP02 Trial
Provision sufficient method and numbers Mix
3 Strength Result Monitor actual strength QC-Concrete-RCD-BP02 Trial
After Trial Mix
Check achieved on 7 days and 28 days Mix;

Actual Compressive Test
Result
Figure 5.1 Salinity check result at the time of trial mixing
90
5.3.2 CONSTRUCTION STAGE
No Time Location Activity Description Record
1 Project Concrete Casting Detail plan on man QC-Concrete-RCD-PR01
Plan power, tools and Casting Plan
equipment prior to
concrete casting time
Batching Condition Check
Plant Conveyor Clean condition, no QC-Concrete-RCD-BP05
excess material Actual Concrete
Monitoring;
Batching Plant Check
Photo Record
Admixture Check zero level of QC-Concrete-RCD-BP05
Dispenser dispenser Actual Concrete
Before Concreting
Monitoring;
Photo Record
Truck numbers Enough truck numbers QC-Concrete-RCD-BP05
to deliver requested Actual Concrete
volume (based on Monitoring
casting plan)
Material Data Actual data for water QC-Concrete-RCD-BP05
adjustment: Fine agg Actual Concrete
moisture content and Monitoring
water absorption; Fly
Ash Sediment Test
Mix Design Check To comply with QC-Concrete-RCD-BP06
requested concrete Mix Design Adjustment
spec and grade Sheet
Batch Adjustment Check correction result
Check after water adjustmentMix Design Adjustment
Sheet
2 Batching Batching Process Check consistency of QC-Concrete-RCD-BP05
Plant Accuracy Check batching accuracy for Actual Concrete
the first 5 truck Monitoring;
During Concreting
Photo Record
Fresh Concrete Check consistency of QC-Concrete-RCD-BP05
Quality Check slump and temperature Actual Concrete
for the first 5 truck Monitoring;
Photo Record
91
2 Project Delivery Inspection Slump and
Temperature to be
checked every truck
During Concreting Cylinder Sample Truck monitoring,
Provision sample code control
QC-Concrete-RCD-
Time Monitoring Truck to be monitored
PR02 Actual
from arrival time until
Concrete
finished unloading
Monitoring
Volume Cumulative volume to
Monitoring be monitored
Placed Concrete Location of placed
Monitoring concrete to be
recorded
3 Project Cylinder Sample Monitor dismantle QC-Concrete-RCD-
Monitoring time, code and curing PR03 Concrete
Monitoring Sheet
Curing Monitoring Monitor curing time for -
After Concreting
each casted structure

Concrete Strength Monitor compressive Actual Compressive
Monitoring strength result of Test Result
concrete cylinder QC-Concrete-RCD-
sample PR03 Concrete
Monitoring Sheet
Structure Checking final result of QC-Concrete-RCD-
Clearance concreting, repair PR04 Structure
Inspection defective Clearance record
Figure 5.2 Actual condition of batching plant shall be checked on inspection. Left-right: 1. Conveyor belt are clean from
unnecessary things. 2. Bins are properly separated within different materials. 3. Admixture dispensers are separated for each type.
92
Figure 5.3 Sample of Batching Record; To Be Check for Every Batching
Figure 5.4 Delivery concrete check, monitor the time and slump test upon concrete delivery
93
5.3.3 TESTING & INSPECTION
Batching Batching Plant Review accuracy of QC-Concrete-RCD-
Plant Process Inspection batching process as per BP08 Process Check
1 SHIMZ requirement Sheet
Material Testing QC-Concrete-RCD-
BP03 Raw Material
Check Sheet
Fine Aggregate FM; Clay Content; Sieve; QC-Concrete-RCD-
SG; Water Absorption; BP03-A Fine
Sampling by SHIMZ Aggregate Analysis
Coarse FM; Clay Content; Sieve; QC-Concrete-RCD-
Aggregate SG; Water Absorption; BP03-B Coarse
Sampling by SHIMZ Aggregate Analysis
Monthly
Raw Material QC-Concrete-RCD-

Review BP03 Raw Material
Check Sheet
Cement OPC Chemical Req.; Physical Actual test result
Type 1 Req. from supplier
Fly Ash Chemical Req.; Physical Actual test result
Req. from supplier
Admixture Chemical Req.; Physical Actual test result
Req. from supplier
Indepen Material Testing
dent Fly As Chemical Req.; Physical Test Report from
Lab. Req. Supplier
Cement Chemical Req.; Physical Test Report from
Req. Supplier
3-monthly
2 Batching Batching Plant Checking condition of QC-Concrete-RCD-

Plant Facilities plant facilities BP04 Facilities
Inspection Check Sheet
3 Indepen Material Testing

6-monthly
dent Fine Aggregate FM; Clay Content; Sieve; Actual 3rd party lab
Lab. SG; Water Absorption report
Coarse FM; Clay Content; Sieve; Actual 3rd party lab
Aggregate SG; Water Absorption report
Indepen Water Chemical Req. Actual 3rd party lab
Annually
dent report
4 Lab. Cement Chemical Req.; Physical Actual 3rd party lab
Req. report
94
6 DEFECT IN PREVIOUS PROJECTS &
PREVENTIVE MEASURES
95
95
6.1 SLAB CRACKS
6.1.1 ROOT CAUSE ANALYSIS

Due to several quality problems that occurred, investigation was held (incorporated with
professional concrete consultant Admaterials from Singapore & Shimizu Institute of
Technology (SIT) Tokyo as a part of Shimizu R&D division) in purpose to find
countermeasures. As a result of investigation, below are explanations regarding root cause
problems and suggested preventive measure for slab cracks problems.
a) Raw Materials
Raw materials; fine & coarse aggregate are main component that forms the concrete.
That is why the quality of raw materials will affect the quality of concrete. Some of
characteristic will affect concrete workability and performance, such as appearances of
shrinkage cracking. Generally, shrinkage cracks occur due to distortion of water content
on mix design. Below listed are some materials characteristic that closely related to
cracks problems.
No Characteristic Requirement Affect(s) of Irregularities

1 Specific Gravity Min. 2.5 Light weight aggregate may
(Dry) have porous surface
It will have more tendency to
absorb water
2 Water Absorption Max. 4% High water absorption will
reduce free water content
Less water may disturb mix
design
3 Material Finer than Fine Agg. Max. 3% Disturb the grading
No. 200 Coarse Agg. Max. 1% Change S/A ratio
Disturb Mix Design
4 Clay Content Max. 3% Clay materials are water
absorbed
Too much clay content will
increase material water
absorption
b) Shape of Casting
In addition, the shape of casting panel may also influence shrinkage cracking issue. If
there is too much difference in width-length ratio, concrete intend to shrink in long
directions and cracks will occur in the opposite way (refer to illustrated picture below).
96
Figure 6.1 Crack direction if slab casted in long shape
For optimum slab performance, the maximum ratio of panel casting size is 1:2 and the
best ratio to cast slab is 1:1 (with recommendation panel size is 10x10m). With this ratio,
the potential of slab shrink in one direction can be reduced & crack will be slightly less to
appear. See drawing below for illustration.
Figure 6.2 (a) Maximum different ratio of slab casting (1:2) (b) Best ratio for slab casting (1:1)
c) Concrete Covering
In relation to concrete cracking, it is important to keep top covering as the designated
value. For better understanding, please refer to below illustrated picture.
Figure 6.3 Illustration; too big concrete cover at top part
In the above illustration, it can be understand that plain concrete is parts of concrete
which is not covered by binding force from top reinforcement bar. Therefore, the
concrete will shrink by itself and crack will start to appear. In order to keep proper
97
concrete cover, it is necessary to maintain the rebar position, which can be achieved by
several controls as follow.
Keep level of LC/Platform/Formwork

Flatness of lean concrete/platform/formwork shall be kept to maintain top covering
depth. Inappropriate level of concrete/platform/formwork may lead to plain
concrete formation. See illustrated picture below.
Figure 6.4 (a) Illustration of bad LC level (b) Illustration of good LC level
Check rebar spacer & concrete cover installation

Rebar spacer & concrete cover are crucial to maintain concrete covering. It shall be
installed in proper condition (see below drawing), so that the rebar arrangement do
not deflect during concreting and required concrete cover can be achieved.
Figure 6.5 Standard of rebar spacer installation
Moreover, Installation of concrete spacer below every rebar spacer is compulsory in

purpose to prevent rebar arrangement deflection due to rebar spacer weight.
Please refer to below illustration for concrete cover installation.
Figure 6.6 Standard of concrete cover installation
d) Mix Design
98
Proportions of mix design will eventually affecting concrete casted performance. In wide
surface casting area such as slabs or walls, compositions of aggregates are very crucial.
Excessive fine aggregate contents will form more mortar volume which characteristically
prone to crack. To prevent such defects, Shimizu Jakarta Office has settled bottom line
requirement for optimum S/A ratio to be 45% (with ±3% tolerance) and also limit water
content to be not higher than 185 Lt/m3.
e) Concrete Delivery & Pouring

Concrete checks during delivery time are important to judge its workability. Once the
concrete is not workable, such as when the slump too slow or segregation appear, it is
very easy for cracks to happen. In addition, when the hard situation happens on site,
worker intends to act careless and add some additional water to overcome workability.
This kind of violation might cause not only cracking problems but also strength problems.
Moreover, while pouring concrete, it is important to control the use of vibrator. Do not
hold vibrator over 10-15 seconds in one place. Over vibration will cause concrete
bleeding (water rise to concrete surface) which will ease evaporation. Rapid evaporation
may cause shrinkage cracking.
As a summary, below listed are checking points during concrete delivery and pouring:
No Time Check Point Purpose
1 Delivery Visual Check Check workability
2 Delivery Slump Check Check workability
3 All the time No water addition Keep mix design
4 Pouring The Use of Vibrator Avoid concrete bleeding
f) Curing
Curing is very important to increase strength, durability, water tightness, & water
resistance. However, the main purpose is to retain water and slow down evaporations.
Rapid evaporation will lead to drying shrinkage cracking.
Figure 6.7 Illustration of Evaporation Mechanism on Concrete
In early stages, it is very crucial to keep concrete in moist condition. For tropical country
like Indonesia, where the room temperature is quite high and sun shines are very strong,
first 7 days wet curing is a mandatory. These are several important items to be paid
attention during curing as below listed:
Supply enough water during setting period (wet curing)

Supply enough water on the first 7 days after casting
Keep proper temperature (not too high or too low)
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Keep away from vibration or external force (at least one day with no work for heavy
moving load to the floor)
Cover concrete after water spray. Commonly, there are 2 types of material used for
wet curing protection, as follow:
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o Curing Mat
Figure 6.8 (a) Curing mat material (b) Sample of curing mat usage
o Plastic Sheet
Figure 6.9 Sample of curing plastic sheet usage
g) Batching Plant Control

Other than the above problems, batching plant control problems also contributes in
preventing slab cracking, especially to all water content related items. Below are several
important check points in batching system that need to be followed in order to keep
good quality of concrete:
Moisture Content & Water Adjustment
Water plays an important role in concrete quality, from workability, performance
until strength development. In relation with cracks prevention, water content may
affect shrinkage behavior.
To understand about moisture content and water adjustment on mixing concrete,
knowledge of material moisture condition is needed. See below illustration.
Figure 6.10 Illustration of material moisture condition
At first, one must understand the state of material assumed in mixing design is on
saturated surface dry (SSD) condition. However, in actual practice, materials cannot
keep in SSD conditions. Particularly in Indonesia, where all the batching plants store
aggregates in open spaces, moisture condition will vary according to weather. Rainy
season will make aggregates wet (or damp) and dry season will make it air dry.
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Understand that free water will react to others ingredients (such as cement,
admixture and others) and will eventually affect concrete quality, it is crucial to
keep its value as the mixing design.
In purpose to keep the mixing design on actual batching, adjustment of water

content needs to be done in every batching to achieve the state of SSD. If material
is in wet condition, water shall be reduced and aggregate shall be added, and vice
versa for material in air dry condition. Adjustment of water content will be based on
actual moisture content (MC). This is the reason why batching plant shall check
moisture content minimum twice a day to keep the accuracy of mixing.
Before discussing on how to adjust the water on actual mixing, one must
understand which MC value to be used on the adjustment. Practically, there are
two ways in determining moisture content. One is total moisture content (TMC)
which determined all water content in the state of material condition, both inside
and outside the particles. The other is surface/free moisture content (FMC) which
only determined water content outside the particles. To calculate water adjustment
for mixing concrete, it needs the value of free moisture content which indicating
free water outside the particles that later will react with other concrete ingredients.
See below illustration for better understanding.
Table 6.1 Moisture Content Test
Moisture Test Illustration Test Test Result Calculation for

Content Method water
Test adjustment
Total Speedy Total Moisture FMC = TMC – WA
Moisture Oven Dry Content (TMC) *Water Absorption
Frying Ratio
Surface Volumetric Free Moisture FMC

Moisture Content (FMC) *directly use for
calculation
If actual aggregates weight express in Aact and free moisture content express in
FMC, then water adjustment detail shall be as mentioned in below table.
Table 6.2 Water adjustment for each moisture condition
Moisture
Condition
Free Water As mixing design Add: Reduce:

(FW) (FWMD) FWMD + (%FMC. Aact) FWMD - (%FMC. Aact)
Aggregates As mixing design Reduce: Add:
(A) (AMD) AMD - (%FMC. Aact) AMD + (%FMC. Aact)
Knowing the importance of moisture content and water adjustment, it needs to

confirm that actual moisture content shall be checked in routine and real time
(highly dependent on weather). Moreover, it also needs to confirm calculation of
102
water adjustment shall be based on free moisture content value. Any violation of
these procedures may change the mixing design and affect the quality of concrete.
As a practical solution, batching plants usually install sprinkler on top of coarse

aggregate stockpile to keep moisture content close to SSD condition.
Figure 6.11 Usage of sprinkler in coarse aggregate stock pile
Actual Batching Record

Actual batching records are necessary to control materials addition and variation.
Excessive amount of each material may change concrete mix design which will lead
to concrete quality problems. Related to crack prevention, please watch over actual
water addition and variation. If some intolerable variations occur, directly contact
batching plant in charge to check on water valve condition to prevent any excessive
water added to concrete mix.
Cleanliness
Both raw materials and batching equipment shall be in a clean condition to prevent
alien substrates mixed in concrete. Raw material cleanliness can be checked
through clay content, while batching equipment cleanliness shall be ensure in daily
basis condition check before every mixing activity.
Any insertion of alien substrates will eventually change the mixing design which
might cause concrete defects, including cracking.
Figure 6.12 Remaining material in weighing & conveyor area
6.1.2 SAMPLE OF PROJECT CASE

a) P&G Baby Care Project (2012)
This project suffers concrete shrinkage cracks (wide varies between 0.1-0.5 mm) which
begin about one month after concrete casting. From the observation made, there are
several possible causes of defects as below:
Shape of Casting
P&G projects slab casting method implies very long casting panel. Each panel size is
around (8x54)m. As mentioned on the above explanations, this condition will cause
103
uneven shrink behavior in X-Y direction. In P&G case, cracks occur in X direction.
Please see below P&G concrete cast monitoring for reference.
Figure 6.13 P&G Panel Casting
Curing
P&G project did not use water for curing. Instead, it used SS harden-X liquid curing
compound. Even though the applications are well controlled, yet it is not sufficient
enough to reduce evaporation rate.
Figure 6.14 Application of SS Harden-X in P&G Project
From the above case, keeping 7 days wet curing is still considered as the best
method to maintain concrete moisture and prevent rapid evaporation which later
lead to shrinkage cracking.
b) KAO KKD Project (2013)
In KAO KKD Project, slab crack occurred not long after casting. Crack width is 0.2 – 0.7.
But not all slab area suffered crack. Crack map are provided and turns out that crack
mostly happened in slab area which casted by specific supplier.
RAW MATERIAL
CASTING RECORD & CRACK MAPPING DATE: 24-Oct-2013 (Fri)
: KARYA BETON :PIONIR :TORSINA :ADHIMIX
26-MAY-2013
PIONIR
21-JUN-2013
KARYA BETON
10-JUN-2013
KARYA BETON
28-JUN-2013
KARYA BETON
12-JUL-2013 PIONIR
1-JUN-2013
KARYA BETON
14-JUL-2013
7-JUL-2013
PIONIR
KARYA BETON
Figure 6.15 Casting area & batching plant inspection

104
In KAO KKD Case, where the cracks mostly occur on Pionir casted panel, let’s take a look
on both Karya Beton’s and Pionir’s mix design.
Figure 6.16 (a) Mix Design Karya Beton (b) Mix Design Pionir
Table 6.3 Comparison Table of Karya Beton & Pionir Mix Design
Items Karya Beton Pionir
Cement (kg) 348 345
Water (Lt) 160 170
W/C 46% 49%
Fine Aggregates (kg) 827 810+90
Coarse Aggregates (kg) 1035 950
S/A 44% 49%
As mentioned on the above comparison table, Pionir has higher water content and S/A
ratio comparing to Karya Beton. With more water and sand, it can be understand that
Pionir’s mix design has more mortar volume.
c) SAMI-JF Project (2014)
Figure 6.17 Part of crack mapping in SAMI-JF Project
In SAMI-JF Project, slab crack occurred around 5 months after casting. Crack width is 0.1 –
0.6. Several problems are observed during investigation on this cracking problem. Below
are detail explanations.
105
Shape of Casting
Shape ratio of slab casting panel averagely is 1:10.
Figure 6.18 Casting area of SAMI-JF
Curing
Similar to P&G project, SAMI-JF also applied liquid curing compound after slab
casting. It is understood from the previous case that application of curing
compound is not effective compared to water ponding method.
Furthermore, worst situation happen in SAMI-JF. This project did not control the
usage of its curing compound. From the record, it is only 10% from the total
material needs that used for the whole projects.
Mix Design
Figure 6.19Pionir Beton Mix Design for SAMI JF Project
Taking example from SAMI-JF case, fine aggregate ratio (S/A) on mix design is
48.5%, which slightly out of SC required. However, it is worsened by material
condition.
Figure 6.20 Coarse aggregates condition on Jepara batching plant
106
Based on actual material testing which is done on concrete investigation by Shimizu
Institute members, it is observed that the coarse aggregate used contains 19.2% of
material finer than no.200 sieve (required contains no more than 1%).
Excessive amount of fine granular in coarse aggregate may affect and change the
proportion of S/A ratio. The designated 48.5% S/A ratio, due to this violence, have
been changed to almost 59%.
Concrete Covering
As mentioned on previous explanation, slab concrete cover especially on top part, is
very important to be kept. In SAMI-JF project, after investigate slab condition using
rebar detector, found out that top concrete cover is out of designated covering.
Figure 6.21 Checking top concrete cover using rebar detector
6.2 LONG SETTING

The main reason for long setting problems is in the content of admixture. Too much
admixtures, or any violation of its dosage may lead to concrete problems such as long setting
and problems in strength developments.
Below are some checking points need to be controlled in purpose to prevent long setting
problems.
a) Control of Admixture Dosage
It is necessary to control usage of admixture based on its dosage. Please notice its dosage
mentioned on the brochure. Usually, the dosage is based on cement content and express
in weight.
Figure 6.22 Example of material dosage based on cement weight

107
However, on concrete batching plant, the measurement of admixture dosage for mixing
was done in volume through admixture dispenser. It is really important to ensure that the
volume based dosage has been adjusted from weight base dosage.
Figure 6.23 Admixture’s dispenser on batching plants
b) Admixture Dispenser on Batching Plant

Remembering that admixture dosages are really sensitive for concrete, its dispenser
condition shall be confirmed. To prevent such defects, Shimizu Jakarta has set up some
standard of admixture dispenser condition.
o Confirm Dispenser Scale Calibration
o Apply Automatic Control (Computerized) for admixture addition
o Separate Dispenser for Each Type of Admixture
o Check Dispenser Valve in a Routine Periods
c) Actual Batching Record Check

Actual batching records are necessary to control materials addition and variation.
Excessive amount of each material may change concrete mix design which will lead to
concrete quality problems, such as segregations, long setting, or even compressive
strength failure. Through the provision of these data, it enables us to analyze the
problems if something went wrong in the future in terms of material composition.
Furthermore, it is also can be used to identify problems and take necessary action to
prevent defects. As an example, refer to below pictures of actual batching records. From
the record we could see there are excessive amount of admixture addition with variation
16-20%. With this information, corrective action can be taken earlier before any
problems occur.
Figure 6.24Batching record, actual admixture variation (left) 16.8% (right) 20.7%
108
d) SIMATUPANG PROJECT
Simatupang project has facing long setting issue in RC column, which cause bad result of
concrete. As seen in picture below, surface crack & color inconsistency appear.
Figure 6.25 Long setting RC column condition; many crack & color inconsistency
This problem was caused by too many admixtures in concrete mixing. After some
investigation done, these are several reason of excess in admixture:
o Wrong Calculation of Admixture Content
Simatupang project was planned to use 0.30% of cement weight for admixture. But
after calculated, found out that the admixture content used is 0.35%. Also in mix
design, the content of admixture is by weight, but batching plant assumes that the
content is in volume basis.
* If 0.30% admixture content of cement weight:
ଵǤ଺ହଽ୩୥
ͷͷ͵ͲǤ͵ͲΨ ൌ ͳǤ͸ͷͻ → ൌ ͳǤͶ݈݅‫ݎ݁ݐ‬
ଵǤଵ଼
*Actual condition (use 1.66 liter/m3):
ͳǤ͸͸‫ͳݔ‬Ǥͳͺ݇݃Ȁ݈݅‫ ݎ݁ݐ‬ൌ ͳǤͻ͸݇݃
ଵǤଽହ௞௚
ൌ ͲǤ͵ͷΨ
ହହଷ୩୥
(So, the admixture used is actually 0.35%, not as original plan (0.30%))
To prevent this problem happen in future, a table of admixture dosage is put in
batching plant.
Figure 6.26 Admixture dosage on batching plant, attached inside mixing room
109
o Uncontrolled Addition of Admixture
In batching plant, admixture dispenser is still in manual way; the operator is pushing
the admixture button without seeing clearly the increment in dispenser.
Figure 6.27 Illustration of manual system of admixture addition
To prevent any human error in manual system of admixture addition, batching plant
changed system of admixture addition, from manual to computerized system. This
computerized system is able to detect the increment of admixture in the dispenser
using sensor.
If the admixture system is computerized, the actual admixture content is able to be
recorded in “batch record”. With this information, if any problem happens in future,
each batch record can be detected easily.
Figure 6.28 Batching record includes admixture addition after computerized system
In order to study & confirm the effect of admixture content to initial & final setting
time, trial mix were done 8 times with different percentage of admixture content
for each. With this such difference, can be seen that even only 0.10% admixture
addition can affect 30-70 minutes difference of setting time.
110
Figure 6.29 Trial mix result to check setting time
Using this trial mix report, project will be able to consider which admixture contents
that appropriate with designated setting time, and also slump test required.
6.3 CONCRETE HONEYCOMB

Concrete honeycomb is the most common defect in concrete works. Most probable reasons
for the defects are due to inappropriate concreting at site. Below are details explanations of
each cause that may lead to concrete honeycomb.
a) Concrete Segregation
Condition of fresh concrete will affect its workability. Segregated concrete may cause
honeycomb problem. See below picture to understand condition of fresh concrete.
Figure 6.30 (a) Normal Concrete Condition (b) Segregated Concrete Condition
111
Figure 6.31 On-Site concrete segregation check
Segregation cause may be comes from internal factors (concrete condition) and also
external factors. Concrete segregation later on will cause honeycomb & even worse,
structural problem. See table below for detail of reason & how to prevent segregation.
No Reason How to Prevent

1 Poorly graded aggregate Control material grading by routine sieve
analysis check (Shimizu standard for raw
material check: once a month)
2 Excess water o Check actual water added on batching

plant & make sure no water added
while on site
o Put on cover on truck mixer while
deliver to site
o Do reverse spin of mixer truck before
loading to take out standing water
3 No proper truck mixer’s Control mixing time as per our
rotation requirement; 1,5 minutes/m3 and another
additional 0,5 minutes for every m3 addition
4 Too high concrete drop Provide proper length of hose, Shimizu’s
standard for maximum concrete drop is 2m
b) Rebar Arrangement
Rebar space
Ensure the minimum space of each bar to bar is more than 1,5x maximum concrete
coarse aggregate size. If the maximum aggregate size is 20mm, rebar space shall be
more than 25mm. The purpose of keeping rebar space is to allow aggregates go within
the rebar. If there is no enough space, only water cement goes through rebar, and it
will lead to concrete honeycomb.
Figure 6.32 Rebar touching each other, no space for aggregate go through the rebar
112
Concrete cover block installation
It is necessary to install proper number of concrete cover block to ensure that the
formwork is not touching the rebar which may obstruct aggregates entering the outer
side. Plastic donut spacer is recommended for column and wall due to its stability in
place.
Figure 6.33 Rebar distance are too close to plywood & no spacer Installed, honeycomb will appear after formwork
removal. Above defect example on (a) wall (b) beam
c) Concreting Method
Vibration
Concrete compaction by using vibrator is essential. Concrete is filled in every corner of
the forms and around the reinforcing bars by adding vibrating and striking the
concrete which have been placed. Vibrating and striking make concrete fluid and can
flush out air bubbles gotten in at the time of placing and prevent occurring of
honeycomb.
However, vibrator usage shall be properly done. If the vibrator is stick in one place for
too long, concrete will bleed and pin holes will come up. On the other hand, if the
timing is too short, concrete will not flow and cause honeycomb. Below are some rules
of vibrating concrete.
o Vertical Moves
Vibrator shall be move up and down within about 20cm.
Figure 6.34 Illustration, up-down movement of vibrator usage
o Horizontal Moves
Vibrator shall be horizontally within about 40-50cm.
113
Figure 6.35 Illustration, left-right movement of vibrator usage
o Placing of Vibrators
Do not use vibrator in manner which will cause concrete segregation after
poring, such as hitting the plywood, touching rebar, etc.
Figure 6.36 Illustration, position of vibrator usage
Free Fall Height & Concrete Pouring

In order to keep concrete in a god shape during casting time, free fall height of casting
shall be in control. If concrete casted with high free fall, it may cause segregation
between paste and aggregates.
For column casting, it is important to keep the free fall not higher than 1,5m. In
addition, it is also necessary to control concrete pouring not to hit the plywood during
flowing because it may cause segregation. See below illustration for good and bad
practice comparisons.
Control Good Practice Bad Practice
Item
Free Fall
Height
114
Pouring
Direction
Formwork Leakage
Leakage in concrete formwork may allow water cement to flow out. This condition
could produce a honeycomb concrete. Especially at bottom of column/wall, where
sometime the free fall is not controlled, it is very important to keep the tightness.
Putting mortar around bottom formwork may help to keep its tightness. See below
illustration for better understanding.
Figure 6.37 Illustration of bottom and corner formwork tightness
Figure 6.38 Example of bottom formwork details to keep water tightness, using rubber sheet below plywood
115
No Photo Reference Possible Cause
1 No vibration during
concreting
[bottom of wall]
2 No cleaning before casting
No enough vibration at the
bottom of the beam
Formwork plywood too dry
[bottom of suspended beams]

3 Formwork leakage at bottom
of foundation girder
Not enough vibration during
casting
[bottom of foundation girder]

4 Formwork leakage at column
joint
casting
[column form joint]
116
5 Lack of concrete cover block
casting
[column face]
6 Inappropriate vibration, too
long stuck in one place
[slab surface]
6.4 CYLINDER TEST FAILURE

Concrete cylinder test result is a representative strength of actual casted concrete on site.
Engineers use this data to judge whether the concrete is acceptable or not structurally.
However, sometimes test result of cylinder sample is failed. Once a project having a failure in
cylinder test, there will be sometimes spend for investigation. This will affect the casting
schedule that will later affect project schedule.
There are several factors that need to control to prevent any failure in cylinder test explained
below.
a) Procedure of Making Cylinder Samples
In making of cylinder sample, tools & procedure shall meet with ASTM C39. Each batching
plant must have certified technician to make cylinder sample. It’s very important to keep
concrete cylinder in good shape with minor defect (no void, no hole in outside surface,
bad finish of top surface).
Figure 6.39 (Left)Bad finish of top concrete surface (Right) Holes around concrete surface
117
Bad condition of concrete cylinder will affect to compression test result. Especially for top
surface of concrete, it needs to be as flat as possible in order to get maximum
compression test result. See illustration below for detail explanation.
Figure 6.40 (Left) Flat surface of cylinder, area is bigger (Right) Not flat surface of cylinder, area is less
As known, F (force in N) = A (area in mm2) x P (Compression in N/mm2). The bigger the

area, the bigger force needed & the higher compression test result. This is why flat
surface is very important in order to get maximum compression test result.
In order to get good concrete cylinder, these are summary of step by step of making
cylinder sample:
1) Prepare all required tool; mold, tamping rod, rubber hammer.
Figure 6.41 Tools for cylinder sampling
2) Fill in concrete in three layers (each is 1/3 of mold). Hit each layer 25 times with
tamping rod, and then punch the surrounding mold 10-15 times using rubber
hammer.
Figure 6.42 Usage of (a) tamping rod in each layer and (b) rubber hammer
3) While hit layer 25 times, ensure the tamping rod is penetrate about 1 inch through
the previous layer.
118
Figure 6.43 Rod shall be penetrated through the previous layer
4) Make top surface of cylinder flat & even using rod, and clean up edge of mold.
Figure 6.44 (a) Finish treatment of top surface (b) Clean up edge of mold using hand
b) Maintenance of Cylinder Samples

Same condition as concrete slab or column, cylinder sample also needs to be kept in
proper condition to get the actual compression test result. These are several conditions
that required for concrete cylinder treatment:
o Protect specimen from direct sunlight & any vibration
o Specimen shall not be transported until at least 8 hours after final set
o After demolding, specimen shall be cured with free water maintained on their
surfaces at all times at ambiance temperature using water storage tanks or moist
room. Below pictures are recommendations of curing pond condition.
Figure 6.45 (a) Proper condition of curing pond (b) Cylinders fully covered with water
c) Surface Preparation Before Testing

Before compression test result, need to be defined that concrete cylinder is in good
condition & flatness. One simple way to check flatness of top cylinder’s surface is to spray
water & close with mirror. If there’s water ponding in the surface, means that the
flatness of concrete cylinder is not good enough. Therefore, surface treatment still need
to be done.
119
Figure 6.46 (a) Not good flatness, water pond still occur (b) Good flatness, no water pond
Above picture is for cube sample. However, this way also can be done for cylinder shape.
Several surface treatments that can be done are grinding (if grinding machine available)
and capping. Each project needs to confirm to laboratory that they provide proper
capping material (using sulfur for normal concrete and gypsum for above 45 MPa
concrete).
Figure 6.47 Sample of surface level check after capping done

In one project case, 28days compression test result of several concrete cylinders not
achieved the required design strength (fc 24). See below pictures for compression test
result.
Figure 6.48 28days compression test result of cylinder with rubber capping
After investigation done, it’s concluded that failure of this compression test is due to usage
of rubber for capping purpose. Rubber has several hardness type, and especially in
120
Indonesia, the hardness of rubber is can’t be controlled. Because of this, SC JKT not allowed
to use rubber as cylinder’s capping. Based on ASTM C617, sulfur is recommended capping
material.
In this case, the project tests the spare concrete cylinder using sulfur capping. All spares
which tested are passed the required design strength.
Figure 6.49 28 days compression test result of cylinder samples with sulfur capping
As reference, an experiment was done in Shimizu Institute in Tokyo regarding the effect of
both cylinder surface and compaction to compression test result. With the same mix design
but different treatment, several cylinders had different compression test result, as below:
Cylinder Code Condition of Cylinder Compression Test Result

1B o No compaction at all 24.4 MPa
o grinded surface
1 o No proper compaction 33.1 MPa
o grinded surface
3 o Proper compaction 35.1 MPa
o grinded surface
3B o Proper compaction 33.2 MPa
o No grinded surface
Figure 6.50 Compression test result comparison
From the data above it can be observed that both surface condition and compaction will
affect the results of compression strength.
121
7 SHIMIZU CONCRETE INVESTIGATION
RECORD
122
7.1 KAO KKD Project
Year : 2013
Lead Engineer : Mr. Nakamura
Subject : Trial Mix & Mix Design
KAO-KKD Project has 4 (four) different concrete suppliers to support the project. In the early
stage of concreting pile cap & ground beam, they have problem with the concrete segregation. It
is assumed that the problems caused by incompatibility of concrete admixture with cement used.
Mr. Nakamura from SIT decided to change mix design and took aggregate samples from each
batching plant, and brought to SIT to be investigate. Below are summaries of changing mix design
& aggregate material test result.
Karya Beton
Adhimix fc'24 Torsina fc'24 Pionir fc'24
No. Items fc'24
Original Final Original Final Original Final Original Final
1 Water-Cement Ratio 54.7% 50% 46% 46% 54.2% 50% 41.3% 49.3%
2 Cement Content 307 340 313 348 325 340 400 345
3 Sand-Agg. Ratio 40.6% 46.6% 45.4% 44.4% 53.8% 47.8% 50.8% 48.6%
Cimalaka 50%; Paseh 90%;
4 Sand Usage Cirebon 100% Bangka 100%
Belitung 50% Purwakarta 10%
Mighty 150R10 (ltr) 1.56 2.3 1.6 1.47 2.6 1.44 3 2.3
5
(% of cement) 0.51% 0.68% 0.51% 0.42% 0.80% 0.42% 0.75% 0.67%
6 Average Strength 30.39 37.9 32.33 37.35 35.56 37.16 33.87 37.54
123
Table 7.1 Characteristic of Batching Plant used in KAO KKD Project
⢒㦵ᮦ (Coarse Aggregate) ⣽㦵ᮦ (Fine Aggregate)

䝥䝷䞁䝖 ⦎ΰ䛬 ྾Ỉ⋡ ྾Ỉ⋡ ஝⇱཰⦰⋡
ྡ ᪉ἲ ⾲஝ẚ ⤯஝ẚ ⾲஝ẚ ⤯஝ẚ Drying
⏘ᆅ % ≉ᚩ ⏘ᆅ % ≉ᚩ
Plant Type 㔜㔜㔜㔜 percentage
Origin Absorbtion Characteristic Origin Absorbtion Characteristic
gr/cm3 gr/cm3 gr/cm3 gr/cm3
ratio ratio
Ἶศ䛾䜋䛸䜣䛹↓䛔ᾏ◁䚸ẕᒾ
Karya ᒾ✀୙᫂䛾○▼ 䛿ⰼᓵᒾ ᑠ䛥䛔
Dry Mix Kusuma 2.58 2.52 1.75 Bangka 2.52 2.48 1.75
Beton Unclear crush stone type Coast sand, less clay content, Small
made from granite
Ἶศ䛾ᑡ䛺䛔⮬↛◁
Paseh 2.64 2.57 2.56 ౑⏝ẚ⋡90%
Natural sand, less clay content.
Blackstone䛸࿧䜀䜜䜛྾Ỉ⋡
ⱝᖸ኱䛝䛔
䛾኱䛝䛔◁ᒾ○▼ ○▼䛾䛖䛱⢏ᚄ䛾ᑠ䛥䛺䜒䛾䜢
Pionir x
Dry Mix Purwakarta 2.55 2.51 1.89 Crush stone which have big ศ⢏䛧䛯⢒䜑䛾○◁
Beton Medium
absorbtion ratio which called Ἶศ䛜ẚ㍑ⓗከ䛔
Purwakarta - 2.46 - high
Blackstone ౑⏝ẚ⋡10%
Coarsed sand contains of small
crushed stone, high clay content
Ἶศ䛾ᑡ䛺䛔⢒䜑䛾⮬↛◁
ᒾ✀୙᫂䛾○▼䚸⢏ᙧ䛜㠀 Cimalaka 2.55 2.46 3.73 ౑⏝ẚ⋡50%
ᖖ䛻ᝏ䛔→s/a䛾኱䛝䛔ཎᅉ Coarsed sand, less clay content ⱝᖸ኱䛝䛔
Torsina
Dry Mix Plered 2.57 2.50 2.74 Unclear crush stone type, very Medium
Redikon Ἶศẚ㍑ⓗከ䛔⣽䜑䛾⮬↛◁
bad particles Æ cause very big high
S/A ratio Belitung 2.55 - - ౑⏝ẚ⋡50%
Smooth sand, high clay content
Ἶศ䛾ከ䛔⮬↛◁
Blackstone䛸࿧䜀䜜䜛྾Ỉ⋡
ୖグ䛜୙㊊䛧䛯ሙྜ䚸ู䛾◁䜢
䛾኱䛝䛔◁ᒾ○▼ 㠀ᖖ䛻኱䛝
Adhimix Wet mix, ౑⏝
BCA 2.60 2.57 1.96 Crush stone which have big Cirebon 2.56 2.44 3.99 䛔
Precast Dry Mix Smooth sand, high clay content.
absorbtion ratio which called Very high
Used if supply of above fine agg.
Blackstone
is not good.
124
7.2 JFE Project
Year : 2014
Lead Engineer : Mr. Nakamura
JFE project built their own concrete batching plant with Shimizu fully involvement in controlling
quality. In the early stage, they have difficulties in designing concrete mix. The concrete they
produced are not workable due to very high slump loss. Investigation results after trial mixing
required them to change the fine aggregates materials. Below are summaries of changing and
remarks for the mix design development on JFE project.
F’c 24 F’c 24 F’c 21 F’c 21

No Items
(Original) (Final) (Original) (Final)
1 Water-Cement Ratio 55% 55% 45% 55%
2 Cement Content 380 kg/m3 340 kg/m3 380 kg/m3 300 kg/m3
3 Sand-Agg. Ratio 50% 50% 41% 50%
4 Sand Usage 70% Tomo 75% Belitung 100% Tomo 75% Belitung
30% Cimalaka 25% Cimalaka 25% Cimalaka
5 Super-plast. Dosage 2.2% 1.6% 2.2% 1.4%
6 Retarder Dosage 0.5% 0 0 0
7 Average Slump Loss 6.5 cm 2.5 cm - 0.5 cm
st
(1 Quarter)
8 Average Strength 32 MPa 36.8 MPa 26.5 MPa 30 MPa
Investigation Summary:
Fine aggregates characteristic are very important related to concrete strength and
workability.
Good raw material selections may enable to reduce cement content and usage of admixture
which will lead to more economic concrete design.
7.3 MNC & ASTRA Tower Project

Year : 2014
Lead Engineer : Mr. Kuroda
In the commencement of those two towers projects, Shimizu institute team supports MNC and
ASTRA to ensure the quality of raw materials used for concrete mix. Investigation result shown
that particular coarse aggregate is prohibited to use due to light weight problems and fly ash
qualities are varies therefore need special control attention.
7.3.1 Coarse Aggregates

After visiting two quarries that used by Adhimix plant, it is observed that one of the two
sources are not good in quality. BGM material is more likely acceptable. However, BBSM
125
material has problems with density. Light weight aggregates found mixed in the stockyard
and some color variation appears.
Figure 7.1 BBSM Material, variation in density test result
As an action towards this finding, Shimizu employed a person in charge in batching plant to
ensure and secure material usage for Shimizu concrete. No BBSM material allowed using.
Signage for coarse aggregate source is attached on the stockyard to prevent loading mistake.
Figure 7.2 Signage on the stockyard
7.3.2 Fly Ash

Early Investigation (2014)
In 2014, Shimizu institute observe Indonesian’s fly ash and compare the results to Japanese
Takehara’s fly ash quality. The observation is done for both physical and chemical properties
of the material. Below are details of results.
126
Physical Properties
ᐦᗘ 䝰䝹䝍䝹䝣䝻䞊 ᅽ⦰ᙉ䛥䠄㻺㻛㼙㼙㻞䠅
ᮦᩱ᥇ྲྀ᪥௜ ⏘ᆅ 㻠㻡䃛⠠ṧศ 䝣䝻䞊್ẚ
㻔㼓㻛㼏㼙㻟㻕㻔㼙㼙㻕㻟᪥ 㻣᪥ 㻞㻤᪥ 㻥㻝᪥
䝁䞁䝖䝻䞊䝹㻔◊✲⏝䝉䝯䞁䝖䠖᪥ᮏ䠅㻟㻚㻝㻢㻝㻣㻜㻙㻞㻠㻚㻝㻟㻥㻚㻡㻡㻢㻚㻟㻢㻢
㻝㻠㻜㻡㻝㻜㻙㼀㻲㻭㼀㼍㼗㼑㼔㼍㼞㼍㻞㻚㻞㻞㻝㻤㻣㻝㻝㻜㻝㻥㻚㻠㻞㻥㻚㻠㻠㻡㻚㻥㻡㻤㻚㻤
㻝㻠㻜㻡㻝㻜㻭㼐㼔㼕㼙㼕㼤㻞㻚㻢㻢㻝㻥㻠㻝㻝㻠㻝㻤㻚㻢㻞㻤㻚㻞㻠㻡㻡㻢㻚㻡
㻝㻠㻜㻢㻞㻜㻭㼐㼔㼕㼙㼕㼤㻞㻚㻣㻡㻞㻜㻠㻝㻞㻜㻝㻥㻚㻞㻟㻜㻚㻡㻠㻤㻚㻠㻢㻣㻚㻝
㻝㻠㻜㻥㻝㻢㻭㼐㼔㼕㼙㼕㼤㻞㻚㻡㻣㻝㻥㻚㻜㻞㻜㻟㻝㻝㻥㻝㻥㻚㻤㻟㻜㻚㻝㻡㻝㻚㻥㻢㻢㻚㻣
㻝㻠㻝㻜㻝㻠㻭㼐㼔㼕㼙㼕㼤㻞㻚㻢㻝㻞㻜㻚㻜㻞㻜㻡㻝㻞㻝㻝㻥㻚㻠㻟㻝㻚㻟㻠㻤㻚㻥
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㼜㼡㼞㼛㼓㼍㼐㼍㼚㼓㻞㻚㻡㻡㻠㻜㻚㻜㻝㻞㻥㻣㻢㻞㻜㻚㻠㻟㻜㻚㻥㻠㻥㻚㻥㻢㻠㻚㻢
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻷㼍㼟㼍㼎㼞㼍㼚㼗㼍㻞㻚㻤㻡㻝㻠㻚㻜㻝㻣㻟㻝㻜㻞㻞㻞㻚㻠㻟㻢㻚㻥㻡㻡㻚㻤
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼕㼙㼍㼠㼛㼜㼍㼚㻞㻚㻡㻜㻝㻡㻢㻥㻞㻞㻜㻚㻞㻟㻜㻚㻞㻠㻥㻚㻝㻢㻠㻚㻣
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼑㼞㼜㼛㼚㼓㻞㻚㻡㻡㻝㻠㻤㻤㻣㻞㻞㻚㻠㻟㻟㻚㻝㻡㻜㻚㻥㻢㻠㻚㻟
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻭㼚㼠㼍㼟㼍㼞㼕㻞㻚㻡㻣㻞㻜㻞㻝㻝㻥㻝㻤㻚㻥㻟㻜㻚㻠㻡㻜㻚㻝㻢㻟
㻝㻠㻜㻢㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻠㻢㻝㻤㻡㻝㻜㻥㻝㻤㻚㻤㻞㻥㻚㻤㻠㻥㻚㻣㻠㻥㻚㻤
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻣㻣㻞㻤㻚㻜㻝㻡㻢㻥㻞㻞㻟㻚㻥㻟㻣㻚㻠㻢㻜㻚㻠㻣㻥㻚㻣
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻢㻝㻟㻝㻚㻜㻝㻤㻢㻝㻜㻥㻝㻣㻚㻟㻞㻤㻚㻟㻠㻢㻚㻠
㻝㻠㻝㻝㻜㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻢㻞㻝㻤㻞㻝㻜㻣㻞㻝㻚㻠㻟㻡㻚㻟㻡㻟㻚㻡
㻝㻠㻝㻝㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻢㻣㻝㻤㻤㻝㻝㻝㻞㻝㻚㻥㻟㻢㻚㻟㻡㻠㻚㻢
㻝㻠㻝㻞㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻢㻟
㻝㻠㻝㻞㻞㻥㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻢㻜
㻝㻡㻜㻝㻞㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻡㻥
㻝㻠㻝㻜㻝㻠㻶㼍㼥㼍㼙㼕㼤㻞㻚㻣㻜㻝㻤㻞㻝㻜㻣㻞㻣㻚㻞㻠㻜㻚㻢㻡㻠㻚㻣
㐣ཤ㻝㻜ᅇ䛾ኚື䛜㻡㻑௨ୗ 䝣䝻䞊పୗ䛿㻶㻵㻿䛾䊢✀䛾 ᙉᗘ䛜㻯㼛㼚㼠㼞㼛㼘䛾㻣㻡㻑௨ୖ
ཧ⪃䠖㻭㻿㼀㻹つ᱁್ 㻭㻿㼀㻹㻌㻯㻌㻢㻝㻤㻙㻜㻟㻙㻙
㻙㻟㻠㻚㻜௨ୗ ዲ䜎䛧䛟䛺䛔㻤㻡䛿ḧ䛧䛔䈜ᙉᗘ䛻䛴䛔䛶䛿඲䛶㻻㻷
㻭㻿㼀㻹つ᱁್䛻ධ䜙䛺䛔䜒䛾
つ᱁್䛿䛺䛔䛜䚸್䛜ዲ䜎䛧䛟䛺䛔䜒䛾
Summary:
ͤ For Adhimix FA, density, flow value ratio, compressive strength are good. FA can
meet JIS requirement. However, for Pionir FA, flow value ratio did not meet the
requirement.
ͤ For Adhimix FA, physical properties could meet ASTM C618-03 while Pionir FA did
not meet requirement for 45P sieve residue test.
ͤ Pionir FA have been recently stable in the result of density test. Previously, the
variation is large.
Chemical Properties
໬Ꮫᡂศ㻔㻑㻕 ⡆᫆ศᯒ䠄䡉䡈䠅
ᮦᩱ᥇ྲྀ᪥௜ ⏘ᆅ
㼕㼓㻚㼘㼛㼟㼟㻿㼕㻻㻞㻭㼘㻞㻻㻟㻲㼑㻞㻻㻟㻯㼍㻻㻹䡃㻻㻿㻻㻟䠄䝅䝸䞁䝎䞊ỿ㝆ヨ㦂㻕
䝁䞁䝖䝻䞊䝹㻔◊✲⏝䝉䝯䞁䝖䠖᪥ᮏ䠅㻜㻚㻣㻝㻞㻝㻚㻟㻝㻡㻚㻜㻥㻟㻚㻝㻢㻢㻡㻚㻠㻠㻝㻚㻜㻝㻞㻚㻜㻞
㻝㻠㻜㻡㻝㻜㻙㼀㻲㻭㼀㼍㼗㼑㼔㼍㼞㼍㻞㻚㻡㻤㻡㻞㻚㻤㻠㻟㻝㻚㻡㻝㻟㻚㻥㻥㻞㻚㻥㻜㻜㻚㻤㻠㻜㻚㻠㻟㻡㻞
㻝㻠㻜㻡㻝㻜㻭㼐㼔㼕㼙㼕㼤㻝㻚㻡㻜
㻝㻠㻜㻢㻞㻜㻭㼐㼔㼕㼙㼕㼤
㻝㻠㻜㻥㻝㻢㻭㼐㼔㼕㼙㼕㼤㻝㻚㻜㻢㻠㻡㻚㻥㻥㻝㻥㻚㻤㻢㻝㻝㻚㻢㻢㻝㻜㻚㻥㻡㻟㻚㻣㻡㻝㻚㻜㻜㻠㻢
㻝㻠㻝㻜㻝㻠㻭㼐㼔㼕㼙㼕㼤㻝㻚㻣㻥㻠㻣㻚㻜㻢㻞㻝㻚㻜㻜㻥㻚㻥㻝㻝㻜㻚㻠㻜㻟㻚㻟㻟㻝㻚㻜㻢
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㼜㼡㼞㼛㼓㼍㼐㼍㼚㼓㻝㻚㻜㻣㻠㻠㻚㻝㻣㻞㻢㻚㻠㻞㻤㻚㻢㻠㻝㻡㻚㻜㻝㻝㻚㻡㻞㻝㻚㻟㻡㻢㻜
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻷㼍㼟㼍㼎㼞㼍㼚㼗㼍㻞㻚㻝㻝㻟㻞㻚㻣㻞㻝㻟㻚㻝㻢㻤㻚㻡㻝㻟㻢㻚㻞㻟㻞㻚㻢㻝㻝㻚㻠㻢
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼕㼙㼍㼠㼛㼜㼍㼚㻝㻚㻢㻜
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼑㼞㼜㼛㼚㼓㻟㻚㻣㻤
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻭㼚㼠㼍㼟㼍㼞㼕㻜㻚㻥㻣
㻝㻠㻜㻢㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻠㻚㻠㻝㻞㻣㻚㻤㻢㻝㻠㻚㻞㻠㻠㻚㻥㻠㻞㻤㻚㻡㻢㻝㻚㻝㻥㻝㻞㻚㻠㻤
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻝㻚㻡㻟㻠㻥㻚㻢㻤㻞㻜㻚㻟㻞㻝㻞㻚㻥㻥㻤㻚㻟㻤㻟㻚㻜㻠㻜㻚㻟㻥㻡㻥
㻝㻠㻝㻝㻜㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻞㻚㻝㻜㻡㻥
㻝㻠㻝㻝㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻝㻚㻥㻜㻡㻤
㻝㻠㻝㻞㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻤
㻝㻠㻝㻞㻞㻥㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻡
㻝㻡㻜㻝㻞㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻟
㻝㻠㻝㻜㻝㻠㻶㼍㼥㼍㼙㼕㼤㻟㻚㻣㻜
䈜㻯㼍㻻ከ䛔
䈜㻡㻡௨ୗ䛜Ⰻ䛔䛸
ཧ⪃䠖㻭㻿㼀㻹つ᱁್ 㻭㻿㼀㻹㻌㻯㻌㻢㻝㻤㻙㻜㻟㻢㻚㻜௨ୗ ㊊䛧䛶㻣㻜௨ୖ ᪥ᮏ䛻䛿↓ 㻙㻡㻚㻜௨ୗ
䛔ရ㉁
᪥ᮏ䛷䛿䛧䛶䛔䜛
㻭㻿㼀㻹つ᱁್䛻ධ䜙䛺䛔䜒䛾
つ᱁್䛿䛺䛔䛜䚸್䛜ዲ䜎䛧䛟䛺䛔䜒䛾
127
Summary:
ͤig.loss, weight loss value at 1000Ԩ. As an index, such as unburned carbon content.
Cylinder sedimentation test for simple quality evaluation of fly ash that is used in japan.
ͤAdhimix fly ash CaO content is larger than those in Japan. Such fly ash did not exist in
Japan so it is not possible to predict the performance.
ͤPionir FA, in some test, chemical analysis result does not meet ASTM specification.
Furthermore, the simple quality tests are taken. Workability is expected to be a very
poor concrete.
Record of Sediment test

⡆᫆ศᯒ䠄䡉䡈䠅
ᮦᩱ᥇ྲྀ᪥௜ ⏘ᆅ 䠄䝅䝸䞁䝎䞊ỿ㝆ヨ㦂㻕
䝁䞁䝖䝻䞊䝹㻔◊✲⏝䝉䝯䞁䝖䠖᪥ᮏ䠅
㻝㻠㻜㻡㻝㻜㻙㼀㻲㻭㼀㼍㼗㼑㼔㼍㼞㼍㻡㻞
㻝㻠㻜㻡㻝㻜㻭㼐㼔㼕㼙㼕㼤
㻝㻠㻜㻢㻞㻜㻭㼐㼔㼕㼙㼕㼤
㻝㻠㻜㻥㻝㻢㻭㼐㼔㼕㼙㼕㼤㻠㻢
㻝㻠㻝㻜㻝㻠㻭㼐㼔㼕㼙㼕㼤
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㼜㼡㼞㼛㼓㼍㼐㼍㼚㼓㻢㻜
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻷㼍㼟㼍㼎㼞㼍㼚㼗㼍
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼕㼙㼍㼠㼛㼜㼍㼚
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻿㼑㼞㼜㼛㼚㼓
㻝㻠㻝㻜㻜㻣㻼㼕㼛㼚㼕㼞㻌㻭㼚㼠㼍㼟㼍㼞㼕
㻝㻠㻜㻢㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚
㻝㻠㻜㻥㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚
㻝㻠㻝㻜㻝㻠㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻥
㻝㻠㻝㻝㻜㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻥
㻝㻠㻝㻝㻞㻜㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻤
㻝㻠㻝㻞㻝㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻤
㻝㻠㻝㻞㻞㻥㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻡
㻝㻡㻜㻝㻞㻢㻼㼕㼛㼚㼕㼞㻌㻿㼡㼐㼕㼞㼙㼍㼚㻡㻟
㻝㻠㻝㻜㻝㻠㻶㼍㼥㼍㼙㼕㼤
䈜㻡㻡௨ୗ䛜Ⰻ䛔䛸
ཧ⪃䠖㻭㻿㼀㻹つ᱁್ 㻭㻿㼀㻹㻌㻯㻌㻢㻝㻤㻙㻜㻟 ᪥ᮏ䛷䛿䛧䛶䛔䜛
128
General Summary
o Particle Size Distribution
In 2014, Indonesia fly ash is slightly coarser than Takehara fly ash made in Japan.
Adhimix fly ash have fine and coarse particle in good combination, but Pionir’s are
dominated by coarse particle only.
4
Takehara
3.5
3 140916-
Sudirman
Frequancy(%)
2.5
140916-
2 Adhimix
141014-
1.5
Kasabranka
1
0.5
0
0.1 1 10 100 1000
Diameter(μm)
st
Figure 7.3 Distribution of particle size in flyash (1 investigation)
Nowadays the distribution of Pionir fly ash stabilizes and is similar to Adhimix. But
150220 samples is far from Adhimix again. The quality of fly ash should be observed
in regular basis.
4
140916-
3.5 sudirman
141106-
3
sudirman
2.5 141216-
Frequancy(%)
sudirman
2
141229-
1.5 sudirman
150125-
1
sudirman
0.5 150220-
sudirman
0
0.1 1 10 100 1000
Diameter(μm)
nd
Figure 7.4 Distribution of particle size in flyash (2 investigation)
o Micro-Structure & Element Analysis

The particle of Takehara and Adhimix fly ash is round shapes. Adhimix fly ash particle
size is not uniform. It shows that small and big particle sizes are mixed. As a
comparison, Takehara has uniform particle size which means more stable.
129
The round shape particle is an important characteristic of fly ash due to its relation
with workability. The more round, workability of fresh concrete will increase.
Figure 7.5 (a) Takehara (b) Adhimix
However, Pionir’s fly ash particle shapes are very bad. It shows that many square and
flaky particles appear instead of round particles. These shapes will cause higher
result on sedimentation test which means the fresh concrete workability may not
perform well.
Figure 7.6 (a) Pionir Sudirman (b) Pionir Kasablanka
In the other hand, quantity of CaO is also an issue in Indonesian fly ash. Because CaO
precede water-cement reaction, concrete strength will rise up earlier, but at the
same time, heat also rises up, that’s why it is not suitable for mass concrete
construction. From the test result, Adhimix fly ash seems to have no problem
because there are not so much CaO.
Another issue is SO3 content in fly ash which strongly will affects concrete
workability. Fly ash with such condition is not allowed to use.
Table 7.2 Content of CaO & SO3 in flyash

No Fly Ash Source CaO Content SO3 Content
1 Takehara* 2.56 1.2
2 Adhimix 13.91 2.88
3 Pionir Sudirman 2014 33.59 13.39
4 Pionir Sudirman 2015 35.03 4.77
130
Deatail Results of Micro-structure and Element Analysis
Takehara Fly Ash
Adhimix Fly Ash
Pionir Sudirman 2014
Pionir Sudirman 2015
131
Further study (2015)
Fly ash from Suralaya power plant is classified as class F according to ASTM C618. The
minimum content of total silica as SiO2, Aluminum as Al2O3 and Ferro as FE2O3 is 70%. Below
are summary of test result conducted by fly ash suppliers each month. After the previous
observation, Shimizu institute continue Indonesian fly ash testing to have an idea of its
quality stability. Below are details summary of testing result.
Equivalent
Sio2+AL2O3 Moisture Loos on Alkalies,
SO3
Concrete +Fe2O3 Content Ignition as Na2O
No Test Date
Supplier ect
(max (max
(max 70%) 5%) (max 6%) (max 3%) 1,5%)
1 Adhimix 6/5/2015 91.66 0.15 0.53 0.62 -
2 Jayamix 3/3/2015 79.26 1.1 0.45 1.24 4.1
3 Jayamix 2/16/2015 84.84 0.46 - 1.15 1.3
4 Pionir 6/1/2015 78.24 0.43 0.48 0.49 0.86
5 Pionir 4/21/2015 81.92 0.54 0.4 0.69 <0,01
6 Pionir 7/18/2014 84.86 0.33 0.56 1.27 1.77
7 Pionir 8/13/2014 77.4 1.08 0.36 0.32 2.45
8 Pionir 9/15/2014 79 0.59 0.44 1.38 0.74
9 Pionir 10/17/2014 86.87 0.33 0.34 2.14 0.75
10 Pionir 11/19/2014 76.8 0.56 0.36 0.58 3.13
11 Pionir 12/15/2014 84.17 0.55 0.52 0.77 2.23
12 Pionir 1/23/2015 74.39 0.62 0.34 0.45 1.5
Karya
13 Beton 1/23/2015 74.39 0.62 0.34 0.45 1.5
Record of Fly ash Sediment Test:
ㄞࡳ್㸸58ml ㏻ᖖ್㸸58ml
132
ㄞࡳ್㸸71ml ㏻ᖖ್㸸58ml ᫂ࡽ࠿࡟␗ᖖࡀㄆࡵࡽࢀࡿ್ 㸦Obviously abnormal
value㸧
ㄞࡳ್㸸55ml㏻ᖖ್㸸58ml
133
㉸⡆᫆ホ౯ἲ㸸ࣇࣛ࢖࢔ࢵࢩࣗ࡜Ỉࢆࠊ㉁㔞ẚ⣙0.5㸦౛㸸ࣇࣛ࢖࢔ࢵࢩࣗ10gࠊỈ5g
㸧࡛⦎ࡾࠊࣇ࣮ࣟࢆィ ࠋᝏ࠸ࡶࡢࡣࠊࡇࡢࡼ࠺࡟ࣇ࣮ࣟࡋࡲࡏࢇࠋ㸦ᕥ㸸ADHIMIX
ࠊྑ㸸ୖࡢᝏ࠿ࡗࡓPIONIR SUDIRMAN㸧
ࡇࡢࡼ࠺࡟ᝏ࠸ࡶࡢࢆ⏝࠸ࡿ࡜ࠊࢥࣥࢡ࣮ࣜࢺࡢ᪋ᕤᛶࡶࡑࢀ࡟క࠸ᝏࡃ࡞ࡾࡲࡍࡢ
࡛ࠊຍỈࡉࢀ࡚ࡋࡲ࠺༴㝤ࡀ࠶ࡾࡲࡍࠋ౑⏝ࡋ࡞࠸࡛ࡃࡔࡉ࠸ࠋ
Simple evaluation: Mixed flyash and water (10g:5g). Bad mixture does not flow. (L: ADHIMIX,
R: PIONIR). This will lead to poor concrete workability. Do not use.
Summary of test results:

Fly ash from Pionir are not allowed to use due to instability of test results and bad particle
shape (flaky instead of rounded)
Projects shall do simple fly ash sedimentation check to review its relation with slump lost
Simple Sedimentation Test for Fly Ash:

Shimizu institute implement sedimentation test for fly ash to study about its relation with
concrete workability. High sediment results may be bad for slump value of fresh concrete.
Test method and detail relation (shown by experimental data) will be elaborate in this
section.
Figure 7.7 Sediment-Slump Relation
Step by step of fly ash sediment test:

Stage 1
Prepare all the equipment & material.
134
Stage 2
Start to do the step 1-4 as in below picture.
Stage 3
Start to do the step 5-6 as in below picture.
135
7.4 Sami JF Project
Year : 2014
Lead Engineer : Mr. Masato Tsujino
Subject : Slab Cracks Investigation
SAMI-JF project suffered crack on slab around several months after casting. Crack width is 0.1-
0.6mm and the clients complained about these situation. Investigation was done by Mr. Tsujino
from Shimizu Institute and mainly focused on raw material condition.
During batching plant visit, Mr. Tsujino did direct test on coarse aggregate in batching plant for
material finer than #200, and found out that the result is 19.2%, while based on ASTM C-33, the
maximum value is 1%. The higher content of fine material or sand, the higher possibility of crack.
WASHING LOSSES TEST (PIONIR)
Pan = 541 gr
initial sample + pan = 4911 gr
initial sample (A) = 4370 gr
washing by sieve No.4 (4.75 mm)
dry sample + pan = 4070 gr

pan = 541 gr
dry smple (B) = 3529 gr
(A) - (B) = 841 gr

% losses = 19.2%
Figure 7.8 Test result of material finer than #200 in coarse agg.
The shape & clay content is the coarse aggregate was also not good. As seen in below picture,
shape of the coarse aggregate is rounded & many clay lumps around. These conditions will very
much affect the durability of coarse aggregate. Clay lumps surround the aggregate will absorb
water, which will decrease unit content of concrete and might cause drying shrinkage.
Figure 7.9 Rounded shape & dirty coarse aggregate
To monitor growth of the crack, several spots are marked and crack was checked in weekly basis.
See below picture mapping & graph of crack’s growth.
136
Figure 7.10 Mapping of crack monitoring
1
No.1 No.2
0.9 No.3 No.4
0.8 No.5 No.6
No.7 No.8
0.7
䜂䜃๭䜜ᖜ䠄mm䠅
No.9 No.10
0.6 No.11 No.12
0.5 No.13 No.14
0.4
0.3
0.2
0.1
0
0 100 200 300 400 500
ᮦ㱋䠄᪥䠅
Figure 7.11 (Left)Relation between crack width & age in days (Right) Condition of crack monitoring
Coring sample was done, and based on this, found that crack is SAMI-JF is shrinkage crack instead
of structural crack because the depth of crack is 50mm out of 230mm slab thickness. See below
picture for coring result.
Figure 7.12 Visual of core sample
For deeper investigation of this shrinkage, several core samples around slab were taken on
February 20th 2015. The age of slab is 6 months already. All core samples were taken to SIT to be
investigated for growth of strain in each sample and make its prediction, which also predict the
crack’s growth.
137
Cables and electricity flow was put above the coring sample. Strain in the core sample will make
the cables stretched, and this information will be read by the red machine beside, which will give
actual strain in the core. With this result, future strain in the concrete can be predicted.
Figure 7.13 Experiment on core slab in SIT
The conclusion on this experiment using electricity flow is that as time goes by, the crack will
grow but the crack’s velocity will decrease. Strain that happens in the concrete will cause hair
crack, but not structural crack, since the strain is still suit with the normal prediction. On the 3rd
year and afterwards, the growth of crack will slightly almost stop. However, the growth of cracks
is comparatively longer than other country. It is because of raw materials characteristics.
7.5 SC JKT Concrete Committee

Year : 2015
Lead Engineer : Mr. Masato Tsujino
Subject : Material Investigation
This investigation is a continuation from previous Jepara concrete problem. As a preventive action
towards cracking and grade failure, SC JKT established concrete committee to set up bottom line
requirements for material properties, production process and casting controls. Shimizu institute,
in this occasion, is helping JKT office in material investigation. Shimizu Institute team has
observed materials not only from batching plants storages but also from the quarry. Below are
summaries of material testing result and recommendation for each fine and coarse aggregates.
138
7.5.2 Fine Aggregates
surface- Water finer
OD
Day of Producing dry absorp than
Taken place Process FM density
collection area condition 3 tion 75μm
3 䡃/cm
䡃/cm 䠄%䠅䠄%䠅
5/20/2015 Redikon_Torsina Cimalaka 3.12 2.56 2.45 4.45

5/20/2015 Redikon_Torsina Cimalaka 3.31 2.56 2.46 4.10
5/20/2015 Redikon2 Cimalaka 3.46 2.48 2.33 6.47
5/20/2015 Redikon2 Cimalaka 3.52 2.47 2.31 6.85
5/21/2015 Adhimix_Dawuan Cimalaka 3.72 2.49 2.35 6.00
5/21/2015 Adhimix_Dawuan Cimalaka 3.39 2.52 2.40 5.23
5/21/2015 Pionir_Karawang Cimalaka 3.56 2.61 2.52 3.57
5/21/2015 Pionir_Karawang Rumpin 3.63 2.43 2.29 5.95
Adhimix_Tanah
5/22/2015 Bangka 3.85 2.54 2.45 3.51
Abang
Adhimix_Tanah
5/22/2015 Belitung 2.75 2.56 2.53 1.16
Abang
5/22/2015 Pionir_Kasablanka Pontianak 2.85 2.59 2.56 1.00
5/22/2015 Pionir_Kasablanka Rumpin 3.29 2.51 2.42 3.53
Jayamix_Kebon Belitung
5/22/2015 3.13 2.57 2.53 1.41
Nanas PAP
5/23/2015 Pion Rumpin 5.42 2.50 2.39 4.67
5/23/2015 Kusumo Rumpin 3.61 2.51 2.39 4.88
5/24/2015 Port Bangka no 2.43 2.62 2.58 1.26 4.66
5/24/2015 Port Bangka sieve 2.95 2.59 2.56 1.20 3.72
5/24/2015 Port Bangka washing 2.77 2.62 2.60 0.72 3.41
5/24/2015 Port Belitung no 2.89 2.60 2.57 0.99 2.30
5/24/2015 Port Lampung no 2.00 2.59 2.56 0.98 3.97

It is not allowed to use M-sand for structural concrete due to high water absorption and
too much dust content.
It is not recommended to use fine aggregate from Cimalaka. Too high water absorption.
It is not allowed to use fine aggregate from Cimalaka for wide surface casting area such
as slabs and walls.
139
7.5.3 Coarse Aggregates
OD Water
Day of Producing SSD
Taken place Classification 3 density absorption
collection area 䡃/cm 3
䡃/cm 䠄%䠅
Coarse 25mm Crushed
5/20/2015 Redikon_Torsina 2.44 2.29 6.19
aggregate stone Purwakarta
Coarse 25mm Crushed
5/20/2015 Redikon_Torsina 2.44 2.30 6.08
Coarse 25mm Crushed
5/20/2015 Redikon2 2.61 2.53 3.22
Coarse 25mm Crushed
5/20/2015 Redikon2 2.63 2.57 2.07
Coarse 10mm Crushed
5/21/2015 Adhimix_Dawuan 2.63 2.59 1.54
Coarse 25mm Crushed
5/21/2015 Adhimix_Dawuan 2.60 2.52 3.15
Coarse 25mm Crushed
5/21/2015 Adhimix_Dawuan 2.59 2.51 3.39
Coarse 25mm Crushed
5/21/2015 Pionir_Karawang 2.56 2.49 3.06
Coarse 20mm Crushed
5/21/2015 Pionir_Karawang 2.54 2.46 3.08
Adhimix_Tanah Coarse 12mm Crushed BGM-
5/22/2015 2.51 2.39 4.99
Abang aggregate stone Rumpin
5/22/2015 2.65 2.61 1.63
5/22/2015 2.60 2.53 3.05
Coarse 25mm Crushed
5/22/2015 Pionir_Kasablanka 2.64 2.58 2.33
aggregate stone Rumpin
Coarse 12mm Crushed
Coarse 25mm Crushed
Coarse 25mm Crushed
Jayamix_Kebon Coarse 12mm Crushed Pion-
5/22/2015 2.53 2.43 4.24
Nanas aggregate stone Rumpin
5/22/2015 2.61 2.55 2.53
5/22/2015 2.60 2.53 2.83
Coarse 25mm Crushed Pion-
5/23/2015 Pion 2.63 2.58 1.87
Coarse 25mm Crushed
5/23/2015 Kusumo 2.62 2.56 2.28
Coarse 25mm Crushed
5/23/2015 BGM 2.56 2.48 3.24
Coarse 25mm Crushed
5/23/2015 Sudamanik 2.58 2.50 3.08

Coarse aggregate which come from Purwakarta area is not good enough due to high
water absorption.
Projects at Jakarta area are recommended to use coarse aggregate from Pion and
Kusumo quarry which have better characteristic than other quarry around Rumpin.
140
8 QUALITY CHECK SHEET
141
8.1 BATCHING PLANT INSPECTION CHECK SHEET
Pre-trial Mix Inspection Check Sheet
Trial Mix Inspection Check Sheet
Raw Material Check Sheet
Fine Aggregate Analysis
Batching Plant Actual Concrete Monitoring
Mix Design Adjustment Sheet
Batching Plant Check Photo Record
Process Check Sheet
Non-Conformance Report (NCR)
142
JAKARTA OFFICE QA/QC CONCRETE COMMITTEE
Doc. Code:
PRE-TRIAL MIX INSPECTION CHECK SHEET QC-Concrete-RCD-BP01 R.00 201504
SUPPLIER :
LOCATION :
DATE :
PART I GENERAL INFORMATION
Supplier Identity :
Name
Address:
Telephone.
Fax
E-mail address
Personnel information:
Plant in charge/Manager
QC personnel
Liaison personnel
Material Testing Facilities
Name of Lab in Charge
Location
Telephone
General Information on Concrete Production Facilities

Name of plant
Type of plant
Plant's rated capacity, m3/hour
Mixture batch size, m3
Truck mixer, Capacity/Nos
Storage Capacity
Coarse aggregates, tonnes
Fine aggregates, tonnes
Crusher fines, tonnes (abu batu)
Water, litres
Admixtures, littres
Retarder
Any other
PART II ADMIXTURE
Dosage confirmation used per o confirmed o not yet confirmed
(if confirmed, to attached the information data from
1m3 of concrete mix supplier)
143
PART III MIX DESIGN APPROVAL
Composition Check
Items SC JKT Requirement Mix Design stated
Cement content min. 300 kg
Water content max. 185 kg
W/C Ratio max. 0.65
S/A Ratio 45 % ± 3 %
Admixture
Type To be stated
Dosage To be stated
Designated Setting Time To be stated
Approved mix design o OK o NOT OK

Approved sign from structure
o OK o NOT OK
designer
Checked by :
(BP person in charge) (SHIMZ QC Staff)
144
Doc. Code:
TRIAL MIX INSPECTION CHECK SHEET QC-Concrete-RCD-BP02 R.00 201504
SUPPLIER :
LOCATION :
DATE :
PART I CONDITION
Conveyor : Clean / No clean
Admixture dispenser : Zero / Not zero
Mixer truck number : o No water stand
o Water stand
PART II MATERIAL DATA
Moisture check method : Oven dry / Speedy / Frying /Flask
Total moisture : % (A)
Water absorption : % (B)
Free moisture
: % (C=A-B)
(for mix adjustment)
Fly ash sedimentation test : …………. mm, shall be less than 55 mm
PART III ACTUAL RESULT CHECK
1 Batch Process Accuracy Check
Jobmix No.
Admixtur
Cement Water Coarse Fine Fly Ash
Grade, Fc' (Mpa) e
1% 1% 2% 2% 3% 1%
2 Slump Lost & Temperature Monitoring

Condition
Grade, Fc' (Mpa) Time Slump Temp.
(Segregation/No)
Fresh Concrete
After Addition of Admixture
After 30 minutes
After 60 minutes
After 90 minutes
Fresh Concrete
After Addition of Admixture
After 30 minutes
After 60 minutes
After 90 minutes
145
3 Salinity Check
Grade, Fc' (Mpa) Salinity Water Coarse Fine Admixture Fly Ash
4 Strength Result Monitoring

Cylinder 7 Days 28 Days 56 Days* %
Grade, Fc' (Mpa) Remarks
Code (MPa) (MPa) (MPa) Strength
*56 Days strength shall be monitored if fly ash used in concrete mix
Checked by :
146
Doc. Code:
BATCHING PLANT INSPECTION CHECKLIST-RAW MATERIAL QC-Concrete-RCD-BP03 R.00 201504
SUPPLIER :
LOCATION :
DATE :
NO ITEMS TO BE CHECK REQUIREMENTS YES NO REMARKS
I Coarse aggregate
Finesses modulus (FM) Max. 8 %
Clay content Max. 5 %
Material Finer than No.200 Max. 1%
Sieve
(1 1/2-in) 37.5-mm 100%
(1-in) 25mm 95%-100%
(1/2-in) 12.5mm 25%-60%
(No. 4) 4.75mm 0%-10%
(No. 8) 2.36-mm 0%-5%
Relative density (SG) > 2.5
Water absorption Max. 4%
II Fine Aggregate
Finesses modulus (FM) 2.3 - 3.1
Clay content Max. 3%
Material Finer than No.200 Max. 3%
Sieve
(3/8-in) 9.5-mm 100%
(No.4) 4.75-mm 95%-100%
(No. 8) 2.36-mm 80%-100%
(No. 16) 1.18-mm 50%-85%
(No. 30) 600-mm 25%-60%
(No. 50) 300-mm 5%-30%
(No. 100) 150-mm 0-10%
Relative density (SG) > 2.5
Water absorption Max. 4%
III Cement (OPC Type 1)
MgO (max %) 6%
SO3 (max %)
C3A ≤ 8% 3.0%
C3A > 8% 3.5%
Loss on Ignition (max %) 5%
Insoluble Residue (max %) 3%
Equivalent Alkalies, as Na2O, etc.
0.6%
(max %)
Air Content (max %) 12%
Time of setting
Initial set (minutes) 45 min
Final set (minutes) 375 min
147
III Cement (OPC Type 1)
Specific Surface (min m2/kg)
Turbid meter test 160
Air permeability test 280
Autoclave expansion (max %) 0.8%
Strength (min)
3 days (kg/cm2) 125
7 days (kg/cm2) 200
28 days (kg/cm2) 280
IV Fly Ash
SiO2+Al2O3+Fe2O3 (min %) 70%
SO3 (max %) 5%
Moisture Content (max %) 3%
Loss on Ignition (max %) 6%
Equivalent Alkalies, as Na2O, etc.
1.50%
(max %)
Finesse (max %) 34%
7 days (min N/mm) 75%
28 days (min %) 75%
Water Req. (max %) 105%
Autoclave expansion (max %) 0.80%
Density (max variation %) 5%
% retained on 45 mm 5%
V Water
Chloride Cl, ppm
Pre-stressed concrete/bridges
500
(ppm)
Other RC in moist environment
1000
containing (ppm)
aluminum embedment or dissimilar
metals
Sulfate as SO4, ppm 3000
Alkalies as (Na2O+0,658K2O),
600
ppm
Potable, no smell,
no color
148
VI Admixture
Trial dosage to
Type A/B/C/D/E/F/G ensure initial
setting
Checked by :
149
Doc. Code:
FINE AGGREGATE ANALYSIS QC-Concrete-RCD-BP03-A R.00 201504
Project :
Supplier :
Material Source :
Sample Location :
Day/Date :
SIEVE ANALYSIS-ASTM C 136-xx
Total Cumulative Cumulative
Percent ASTM C 33
Sieve Size Mass Percent Percent
Retained %PASSING
Retained Retained Passing
3/8" 100
#4 95 to 100
#8 80 to 100
#16 50 to 85
#30 25 to 60
#50 10 to 30
#100 2 to 10
PAN
FM :
(6Cum. Retained)/100 2.3-3.1
MOISTURE WASH LOSS SG & ABSORPTION
ASTM C566-xx ASTM C 117-XX ASTM C 128-xx
Wet mass Initial dry mass SSD Mass (g)
Dry mass Dry mass after wash Water Disp. (g)
Difference Difference SG
% Total moisture % Finer than 200 Dry Mass (g)
% Absorption Difference
% Free moisture Spec. requirement Max. 3% % Absorption
ORGANIC IMP. ASTM C 40-xx
Color plate No.

Spec. requirement Organic plate No.3 (color dark no.11)
REMARKS :
Checked by :
(BP Person in charge) (SHIMZ QC in charge)
150
Doc. Code:
COARSE AGGREGATE ANALYSIS QC-Concrete-RCD-BP03-B R.00 201504
Project :
Supplier :
Material Source :
Sample Location :
Day/Date :
SIEVE ANALYSIS-ASTM C 136-xx
Total Cumulative Cumulative

Percent Percent ASTM C 33
Sieve Size Mass Percent Percent
Retained Passing %PASSING
Retained Retained Passing
(1 1/2-in) 37.5-mm 100
(1-in) 25mm 95-100
(1/2-in) 12.5mm 25-60
(No. 4) 4.75mm 0-10
(No. 8) 2.36-mm 0-5
PAN
FM [900-6 Blue Marked % Passing]/100 Max. 8
MOISTURE WASH LOSS SG & ABSORPTION

ASTM C566-xx ASTM C 117-XX ASTM C 128-xx
Wet mass Initial dry mass SSD Mass (g)
Dry mass Dry mass after wash Water Disp. (g)
Difference Difference SG
% Total moisture % Finer than 200 Dry Mass (g)
% Absorption Difference
% Free moisture Spec. requirement Max. 1% % Absorption
REMARKS :
Checked by :
(BP person in charge) (SHIMZ QC in charge)
151
Doc. Code:
BATCHING PLANT INSPECTION CHECKLIST-FACILITIES QC-Concrete-RCD-BP04 R.00 201504
SUPPLIER :
LOCATION :
DATE :
I MATERIAL STOCK
1) Stock pile
Separator shall be high enough, no
Compartment
mixed material
Floor Concrete floor shall be provided
2) Silo
Efficient discharge, not exceed
Hooper
allowable tolerance (±1%)
Calibration Once in 6 month
3) Water tank
Capacity Sufficient for daily need supply
II TESTING TOOLS & EQUIPMENT
1) Moisture test
Total Moisture Ventilated oven/speedy/frying
Surface Moisture Flask with ≤ 0,5ml scale increment
2) Sieve analysis
Coarse aggregate Depends on max agg. Size
Fine aggregate Depends on max agg. Size
3) Clay Content
Container Non-rust material
No.4; No.8; No.20; for Clay Lumps
Sieve
No.200 for material finer than 200
Drying oven Ventilated oven
4) Relative density (SG)
Balance Accurate to 0.05 kg
Tamping rod Dia. 16mm, length 600 mm
Scoop Convenience with agg. Size
Plate glass 25 mm larger than measure dia.
5) Water absorption
Balance Sensitivity 0.1 gr or less
Pycnometer/Flask 50 % more than sample volume
Mold and tamper Made from steel
152
II 6) Slump test
Cone Standard cone for slump test
Plate Good condition of flatness
Stick Dia. 16 mm, length 600 mm
7) Temperature
Scale readable to 0.5oC ; increment
Scale
throughout a range of 0-50oC
Calibration Shall be calibrated annually
8) Sampling
Cylinder Inside dia. 150±2 mm,
Stick height 300±6 mm
No leakage, free from vibration
Curing pond
and direct sunlight
9) Compressive strength test
Scales to return to zero, Capacity of
Machine stress shall be more than
designated concrete strength
Calibration Shall be calibrated annually
BATCHING TOOLS AND
III
EQUIPMENT
1) Bins
Fully separated, No contamination,
Separator
No overflow to conveyor belt
Signage to indicate usage of bins
Marking
for every material type
Screen mesh 100 mm x 100 mm
Efficient discharge, not exceed
Hooper
allowable tolerance ( ± 2 %)
Shall be free from other substance
2) Conveyor belt except particular material that
being weight
3) Weighing control/Scales
Cement/Fly ash ± 1 %; Aggregate ±
Tolerance
2 %; Water ± 1 %; Admixture ± 3 %
Calibration Once in 6 months
4) Dispenser for admixture
Shall be separated for each of
Separation
admixture type
Shall be controlled flow
Discharge Method
(computerized)
Clear mark for scale; Start from
Scale
zero while loading
5) Water tank
Shall be separated for each of
Separation
admixture type
Shall be controlled flow
Discharge Method
(computerized)
153
III 6) Mixer
Provided with acceptable timing
device that will not permit the
Timing
batch to be discharged before the
specified mixing time has elapsed
Condition Clean, no concrete waste
7) Mixer Truck
Volume capacity shall be 37 %
Capacity
more than concrete volume
Revolution min. 70-100 RPM
Cleanliness shall be maintained;
Condition
CALIBRATION &
IV
CERTIFICATION
1) Weighing control Once in 6 months
2) Dispenser Once in a year
3) Compressive machine Once in a year
4) Thermometer Once in a year
5) Laboratory balance Once in a year
Checked by :
154
Doc. Code:
BATCHING PLANT ACTUAL CONCRETE MONITORING QC-Concrete-RCD-BP05 R.00 201504
SUPPLIER :
LOCATION :
DATE :
PART I CONDITION
Conveyor : Clean / No clean
Admixture dispenser : Zero / Not zero
Mixer truck number : Casting plan : Truck
Actual : Truck
PART II MATERIAL DATA
Moisture check method : Oven dry / Speedy / Frying /Flask
Total moisture : % (A)
Water absorption : % (B)
Free moisture
: % (C=A-B)
(for mix adjustment)
shall be less than 55
Fly ash sedimentation test : …………. mm,
mm
PART III CONSISTENCY CHECK
1 Batch Process
Grade/ Job Mix No. :
Actual Batch per Truck Mixer No.
Composition Req.
1 2 3 4 5
Water 1%
Coarse Agg. 1%
Fine Agg. 2%
Fly Ash 2%
Admixture 3%
2 Fresh Concrete Check

SLUMP (cm) TEMP. (oC)
GRADE/JOB MIX CODE TM
Req. Actual Req. Actual
1
2
3
4
5
Checked by :
155
Doc. Code:
MIX DESIGN ADJUSTMENT SHEET QC-Concrete-RCD-BP06 R.00 201504
Project :
Supplier :
Material Source :
Sample Location :
Day/Date :
o o
Weather Conditions: Air Temp: AM C PM C
Aggregate Cooled: Yes □ No □ Ice: Yes □ No □
Delivery load in m3: Mixing Method: Central Mixer □ Truck □
Design Mix Str. Class: Design Slump:
1 m3 DESIGN PROPORTIONS
Fly Admix
Cement Fine Agg. (kg) Coarse Agg. (kg) H2O
Ash (kg)
kg kg Type SSD M% Adjust SSD M% Adjust kg #1 #2
M. Sand
Nat Sand
Mix Proportions per batch
M. Sand
0 0 Nat Sand
Batch Weights Material/Sources

Material Actual Batch Difference % Actual Difference Tolerance
Cement 1%
Fly Ash 1%
Fine Agg. 2%
Coarse Agg. 2%
Mixing H2O 1%
Admix #1 3%
Admix #2 3%
Mixing Water Calculations

Water in F. Agg. Design Mix Water
Water in C. Agg . Adjusted Mix Water
Total Water in Agg. (Design-Total water in Agg.)
Moisture Calculations
F. Agg. Wet Mass C. Agg. Wet Mass
Dry mass Dry Mass
Difference Difference
_________________________ ___________________
SHIMZ QC
BP Person in charge Staff
156
Doc. Code:
BATCHING PLANT CHECK PHOTO RECORD QC-Concrete-RCD-BP07 R.00 201504
SUPPLIER :
LOCATION :
DATE :
Conveyor Bottom of Hooper Condition Conveyor Belt Condition

Photos
Admixture Dispenser Type 1 Dispenser Type 2

Dispenser
Fresh Concrete Condition Slump Test

Concrete
157
Doc. Code:
BATCHING PLANT INSPECTION CHECKLIST-PROCESS QC-Concrete-RCD-BP08 R.00 201504
SUPPLIER :
LOCATION :
DATE :
I MATERIAL DELIVERY CHECK
1) Coarse aggregate
Visual check Compare with master sample
2) Fine aggregate
Visual check Compare with master sample
II REGULAR TESTING
1) Moisture content
sample taken 30cm from
Sampling
surface
Frequency 2 times a day + after raining
Total moisture Use microwave oven on 110oC
Use flask with ≤ 0.5ml scale
Surface Moisture
increment
2) Sieve analysis
Sampling
surface
Frequency Once a month
Method No wash out, Dry Condition
3) Relative density (SG)
Sampling
surface
Done both dry and SSD
Method
condition
4) Water absorption
Coarse aggregate Once a month
Fine Aggregate Once a month
5) Fly ash sediment test
No more than 55ml
Result
sedimentation
158
III BATCHING
1) Water adjustment
Frequency Every batch
Based on moisture content
Judgment
result
2) Material addition
Coarse aggregate ±2%
Fine aggregates ±2%
Cement ±1%
Fly ash ±1%
Water ±1%
Admixture ±3%
3) Mixing Not less than 1.5 minutes for 1
m3 and additional 0.5 minutes
for every1 m3 volume addition
4) Truck loading No water inside mixer, confirm
by reverse spin of mixer
IV AFTER BATCHING
3 layers, 25 times stroke each
1) Slump test
layer, within 2,5 minutes
Max. temperature use 38OC if
2) Temperature check
not mentioned in specification
3) Sampling
3 layers, 25 times stroke each
Procedure
layer, trowel finished
Min 2 for each 7 days, 28 days
Cylinder Numbers
and spare
Representative one set per 115m3 volume or
Amount 465m2 surface
4) Specimen curing
Pond No leakage, clean water
Free from vibration and direct
Location
sunlight
5) Compressive Test
> 45 MPa use gypsum capping;
Capping
≤ 45 MPa use sulfur capping
Checked by :
159
Doc. Code:
NON-CONFORMANCE REPORT QC-Concrete-RCD-BP09 R.00 201504
Concrete Supplier :
Batching Plan :
Inspection Day/Date :
Inspector(s) :
Batching Plan PIC :
Non-Conformance Item Requirements
Description: Doc. Ref.: QC-Concrete-STD-RQ02
Concret
No separation between fine Concrete Plant Facilities
ete Batching Plan
and coarse aggregate stock Stock pile compartments
compartment shall be fully
pile. Contamination
n may separated, no contamination
contamina with
occur. concrete floor or control ffor materials
usage to not use 30cm from bottom
part.
Action To Be Taken:
Provide full wall
all separator with concrete floor (Confirm
(Confirmation: Photo Record)
Rectification Deadline:
eadline: Verification :
Verificatio Remarks :
(TBC) OK
NOT OK
Description: Doc. Ref.:
Action To Be Taken:
Rectification Deadline: Verification : Remarks :

OK
NOT OK
Action To Be Taken:

OK
NOT OK
160
8.2 SITE INSPECTION AND MONITORING SHEET
Concrete Casting Plan
Site Concrete Casting Monitoring
Concrete Monitoring Sheet
Structure Clearance Record
Notice of Improvement (NOI)
161
Doc. Code:
CONCRETE CASTING PLAN QC-Concrete-RCD-PR01 R.00 201504
approved by approved by check by prepared by
Project Name :
Date : Time Plan :
Location : Actual :
CONCRETE ONCE CYCLE DELIVERY
Grade : Test Cylinder (6 Cyl/set) each 120 m³
Slump : Time 7 days 14 days 28 days

Concrete
Mix : in Batching Plant
Quality
Volume Plan : ………... m³ Structural 㼙㼕㼚㼡㼠㼑㼟
Actual : ........ m³ Quality 㻯㻭㻿㼀㻵㻺㻳㻌㻿㼀㻭㻾㼀㻯㻭㻿㼀㻵㻺㻳㻌㻲㻵㻺㻵㻿㻴
Number of Mixer Truck : TOTAL = (spare) = Cylinder

Casting Method : 㼙㼕㼚㼡㼠㼑㼟㼙㼕㼚㼡㼠㼑㼟
Temperature : 28.3˚C - 29.3˚C
Equipment Conc. Pump : 1 unit 㻻㻺㻌㻿㻵㼀㻱㻻㼁㼀㻌㻿㻵㼀㻱
Vibrator : 2 unit
㼙㼕㼚㼡㼠㼑㼟㼙㼕㼚㼡㼠㼑㼟
Trowel machine : 2 unit LOADING = minutes
Compressor : 1 unit
㻼㻸㻭㻺㼀
Spread machine : 1 Unit
RESOURCES KEY PLAN
Manpower Plan Actual Person In Charge
SC Staff Concrete Order
Concretor : Concrete Deliverer
- Pump Casting (Discharge)
- Vibrator Foreman
- Mason Temperature/Slump
- Carpenter Rebar & Cleaning
- Barbender Safety
- Helper Batching Plant
- Cleaning Surveyor
- Trowel Finish
- Mechanical & Electrical
TOTAL 0 0
REMARKS
DESCRIPTION SCHEDULE of DELIVERY
DELIVERY
120 5 10 5 120 10
1 m³
120 5 10 5 120 10
2 m³
30 120 5 10 5 120 10
3 m³
120 5 10 5 120 10
4 m³
120 5 10 5 120 10
5 m³ 1 CYCLE OF
120 5 10 5 120 10
6 m³ MIXER TRUCK
( 10 UNIT) 120 5 10 5 120 10
7 m³
120 5 10 5 120 10
8 m³
120 5 10 5 120 10
9 m³
120 5 10 5 120 10
10 m³
120 5 10 5 120 10
Eighteen Times Delivery
11 m³
120 5 10 5 120 10
12 m³
120 5 10 5 120 10
13 m³
120 5 10 5 120 10
14 m³
120 5 10 5 120 10
15 m³
120 5 10 5 120 10
16 m³
120 5 10 5 120 10
17 m³
120 5 10 5 120 10
18 m³
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 # 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 # # # 126 127 128 129 130 131 132 # # 134 135 136 137 # 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156
TOTAL 0 m³ NOTE :
ANALISYS
Duration Volume (m³) Batching Plant to Site ±
180 minutes
0
3.00 hour
1 hour 0
162
163
Doc. Code:
SITE CONCRETE CASTING MONITORING QC-Concrete-RCD-PR02 R.00 201504
Date :
Concrete Supplier :
Concrete Grade :
Slump Design :
CASTING MIXER RECORD VOL CUM SPECIMEN

No LOCATIO TRUCK REMARKS
N No.
BATCH ARRIVE SLUMP TEMP POURING FINISH M³ M³ Code NOS
RECEIVED&CHECKED BY : CONFIRMED BY :
(LOGISTIC/QC Asst.) ( )
NAME: NAME:
DATE: DATE:
164
Doc. Code:
CONCRETE MONITORING SHEET QC-Concrete-RCD-PR03 R.00 201504
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165
Doc. Code:
STRUCTURE CLEARANCE RECORD QC-Concrete-RCD-PR04 R.00 201504
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㻵㻌㻦㻌㻰㼑㼜㼠㼔㻌㻝㻜㼪㻟㻜㼙㼙㻵㻦㼀㼔㼑㼞㼑㻌㼕㼟㻌㼐㼑㼎㼛㼚㼐㼕㼚㼓㻌㼓㼍㼜㻌㼍㼠㻌㼖㼛㼕㼚㼠㻚㻿㼡㼎㼟㼠㼍㼚㼏㼑㻕㻱㼤㼠㼑㼞㼕㼛㼞㻻㼠㼔㼑㼞㼟
㻙㻙㻭㼓㼓㼞㼑㼓㼍㼠㼑㻌㼜㼕㼘㼘㻌㼛㼒㼒㻌㼜㼍㼞㼠㼕㼍㼘㼘㼥㻚㻵㻵㻦㼀㼔㼑㼞㼑㼕㼟㻌㻴㼛㼚㼑㼥㼏㼛㼙㼎㻌㻸㼑㼢㼑㼘㻵㼍㼚㼐㻌㻵㻵㻚㻵㻌㻦㻌㻜㻚㻜㻢㼙㼙㻨㻩㼣㼕㼐㼠㼔㻨㻜㻚㻞㼙㼙
㻵㻵㻌㻦㻌㻰㼑㼜㼠㼔㻌㻟㻜㼪㻝㻜㻜㼙㼙㻵㻵㻵㻦㼀㼔㼑㼞㼑㼕㼟㻌㻴㼛㼚㼑㼞㼏㼛㼙㼎㻌㻸㼑㼢㼑㻌㻵㻵㻵㻚㻵㻵㻌㻦㻌㻜㻚㻞㼙㼙㻨㻩㼣㼕㼐㼠㼔㻨㻜㻚㻡㼙㼙
㻙㻙㻭㼓㼓㼞㼑㼓㼍㼠㼑㻌㼜㼕㼘㼘㻌㼛㼒㼒㻌㼏㼛㼚㼠㼕㼚㼡㼕㼠㼥㻵㻵㻵㻌㻦㻌㻜㻚㻡㼙㼙㻨㻩㼣㼕㼐㼠㼔
㻵㻵㻵㻌㻦㻌㻰㼑㼜㼠㼔㻌㼙㼛㼞㼑㻌㼠㼔㼍㼚㻌㻝㻜㻜㼙㼙㻵㼚㼠㼑㼞㼕㼛㼞
㻙㻙㻹㼛㼟㼠㻌㼛㼒㻌㻭㼓㼓㼞㼑㼓㼍㼠㼑㻌㼜㼕㼘㼘㻌㼛㼒㼒㻚㻵㻵㻌㻦㻌㻜㻚㻟㼙㼙㻨㻩㼣㼕㼐㼠㼔㻨㻜㻚㻡㼙㼙
㻵㻵㻵㻌㻦㻌㻜㻚㻡㼙㼙㻨㻩㼣㼕㼐㼠㼔
166
Photo Sheet
㻌
㻌 >An object of Level I, II
Before rectification
㻌 >Mention Defect No. and
Position Location
>Paste phot before rectification Position
(After formwork removal)
After Chipping Condition
>Paste photo after chipping Level of Defect
Remarks
-How many mm honeycomb depths
-How many mm crack width
After rectification
㻌 Location
㻌 >An object of Level I, II
㻌 >Mention Defect No. and Position
Position
>Paste phot after rectification Description & Level
>Paste photo of chipping

progress, rectification material,
rectification progress and so on. Location
Position
Material
Method and Progress
167
Rectification Method
A- Honeycomb
Reference Rectification
Level Standard Sketch
Method
Aggregates are 1. Remove aggregate which

appeared. exposed more than half size.
Combination strength 2. Damp surface.
of aggregate is so 3. Apply bonding agent. 㻌㻌㻌㻌㻌
I
strong that it shall not 4. Touch up with non-shrink
pill of automatically. mortar.㻌㻌㻌㻌㻌㻌㻌
Depth is about 5. Apply non shrink cement
10~30mm. paste to surface.
1. Remove aggregate which

Rebar is appeared. exposed more than half size.
Hollow is visible. 2. Damp surface.
Combination strength 3. Apply bonding agent. 㻌㻌㻌㻌㻌
II of aggregate is so 4. Touch up with non-shrink
weak that is can be mortar or grout with non-
removed easily. Depth shrink grout.㻌㻌㻌㻌㻌
is about 30~100mm. 5. Apply non shrink cement
paste to surface.

exposed more than half size.
Many hollows are
2. Damp surface.
visible inside of
3. Touch up
concrete. Aggregate is
a. Cast back with design
combined by cement
III strength concrete.
paste and can be
b. Grout non shrink grout.
removed very easy.
c. Touch up with non-shrink
Depth is more than
mortar. 4.
100mm.
Apply non shrink cement
paste to surface.
‫۔‬method of chipping ① Chipped out defective part defective part shall be chipped by
breaker/or Hand up to concrete surface to be Proper concrete. Loose
concrete part shall be chipped out clearly
② Clean & wetting after chipping preparation shall be done in
accordance with manufacturer's recommendations.
168
B- Cold Joint
Level Standard Sketch Reference Rectification Method
[Water tightness of external

wall]
1. U cut at joint depth
10~20mm.
2. Apply sealant. 3~4mm remain
from surface. 3.
Apply sand at surface of sealant.
4. Apply non shrink mortar.
5. Apply non shrink mortar paste
De-bounding gap at at surface. 㻌㻌㻌㻌㻌㻌㻌㻌㻌㻌㻌㻌
I Joint
[Exposed concrete or Tile

finishing]
Close gap without U cut.
(Direct sealant)
[Structural Component (External
surface)]
Width >= 0.2mm : Inject Epoxy
resin. Width <
Width more than 0.2 0.2mm : Follow method for
mm : Rebar will be "External Wall"
rusty.
[Structural Component
(Interior)]
Width >= 0.3mm : Inject Epoxy
resin.
[Others]
Width >= 0.3mm : Touch up
with Epoxy resin.

exposed more than half size.
2. U cut depth 10~20mm at de-
bounding joint.
There is Honeycomb
II Refer Honeycomb Level I and II. 3. Apply sealant. 3~4mm remain
Level I or II at Joint.
from surface. 㻌㻌㻌 4.
Apply sand at surface of sealant.
5~ Follow method for
Honeycomb Level I and II.
There is Honeycomb Follow Method of Honeycomb

III Refer Honeycomb Level III
Level III at Joint. Level III.
169
D- Cracks
<External Surface>
Level Standard Remark
Method
Finishing
Textured Paint
Rectification is not required.
Plastering
Tile (with plastering)
0.06mm <= Width <
I Finishing
0.2mm
Acrylic Resin
Textured Paint (Not elastic) Follow Level II
Exposed concrete
Tile (without plastering)
U cut and applies elastic
sealant and non-shrink mortar
paste.
[Exposed concrete, Tile
(without plastering)]
Close crack without U cut.
ex. Direct sealant
0.2mm <= width <
II
0.5mm
[Column, Beam and structural
Wall]
Epoxy Injection
[Structural Wall]
U cut and applies elastic
sealant and non-shrink mortar
paste.
III 0.5mm <= width Follow Level II
<Interior>
Level Standard Remark
Method
0.06mm <= Width <
I Rectification is not required.
0.3mm
Close crack without U cut
Direct sealant.
II 0.3mm <= width <
<Column, Beam, Structural
0.5mm
Wall, Slab>
Epoxy Injection.
III 0.5mm <= width Follow Level II
‫۔‬Method of Crack Measurement: ①Measuring by crack scale

②To be measured at Crack
Gaps not at Gaps with edge
deficit.
170
Doc. Code:
NOTICE OF IMPROVEMENT QC-Concrete-RCD-PR05 R.00 201504
Project :
Location :
Inspection Day/Date :
Inspector(s) :
Project PIC :
Non-Compliance Item Requirements
Description: Doc. Ref.: QC-Concrete-STD-RQ02
Concret
No separation between fine Concrete Plant Facilities
rete Batching Plan
and coarse aggregate stock Stock pile compartments
compartment shall be fully
pile. Contamination
n may separated, no contamination
contamina with
occur. concrete floor or control ffor materials
usage to not use 30cm from bottom
part.
Action To Be Taken:
Provide full wall
all separator with concrete floor (Confirm
(Confirmation: Photo Record)
Rectification Deadline:
eadline: Verification :
Verificatio Remarks :
(TBC) OK
NOT OK
Action To Be Taken:

OK
NOT OK
Action To Be Taken:

OK
NOT OK
171
9 AUDIO VISUAL REFERENCES
172
Contents:
ASTM C172 Sampling Freshly Mixed Concrete
ASTM C143 Concrete Slump Test
ASTM C2064 Concrete Temperature Test
ASTM C31 Making Concrete Cylinder
Quality Control of Concrete on Site (PART1)
Quality Control of Concrete on Site (PART 2)
173
LIST OF REFERENCE
ACI Committee 318, “Building Code Requirements for Structural Concrete (ACI 318-11) and
Commentary”, American Concrete Institute, Farmington Hills, Michigan, 2011.
ACI Committee 311, “ACI Manual of Concrete Inspection”, American Concrete Institute, Detroit,
1984.
ASTM C 29, “Standard Test Method for Bulk Density (Unit Weight) and Voids in Aggregate”,
ASTM International, West Conshohocken, 2003.
ASTM C 31, ”Standard Practice for Making and Curing Concrete Test Specimens in The Field”,
ASTM International, West Conshohocken, 2003.
ASTM C 33, “Standard Specification for Concrete Aggregates”, ASTM International, West
Conshohocken, 2003.
ASTM C 39, “Standard Test Method for Compressive Strength of Cylindrical Concrete
Speciments”, ASTM International, West Conshohocken, 2003.
ASTM C 70, “Standard Test Method for Surface Moisture in Fine Aggregate”, ASTM
International, West Conshohocken, 2001.
ASTM C 94, “Standard Specification for Ready-Mixed Concrete”, ASTM International, West
Conshohocken, 2004.
ASTM C 127, “Standard Test Method for Density, Relative Density (Specific Gravity) and
Absorption of Course Aggregate”, ASTM International, West Conshohocken, 2001.
ASTM C 128, “Standard Test Method for Density, Relative Density (Specific Gravity) and
Absorption of Fine Aggregate”, ASTM International, West Conshohocken, 2001.
ASTM C 136, “Standard Test Method for Sieve Analysis of Fine and Course Aggregates”, ASTM
ASTM C 138, “Standard Test Method for Density (Unit Weight), Yield and Air Content
(Gravimetric) of Concrete”, ASTM International, West Conshohocken, 2001.
ASTM C 142, “Standard Test Method for Clay Lumps and Friable Particles in Aggregates”, ASTM
ASTM C 143, “Standard Test Method for Slump of Hydraulic-Cement Concrete”, ASTM
ASTM C 150, “Standard Specification for Portland Cement”, ASTM International, West
Conshohocken, 2007.
174
ASTM C 172, “Standard Practice for Sampling Freshly Mixed Concrete”, ASTM International,
West Conshohocken, 1999.
ASTM C 494, “Standard Specification for Chemical Admixture for Concrete”, ASTM International,
West Conshohocken, 2004.
ASTM C 566, “Standard Test Method for Total Evaporable Moisture Content of Aggregate by
Drying”, ASTM International, West Conshohocken, 2004.
ASTM C 617, “Standard Practice for Capping Cylindrical Concrete Specimens”, ASTM
ASTM C 618, “Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for
Use in Concrete”, ASTM International, West Conshohocken, 2003.
ASTM C 685, “Standard Specification for Concrete Made by Volumetric Batching and Continuous
Mixing”, ASTM International, West Conshohocken, 2001.
ASTM C 1064, “Standard Test Method for Temperature of Freshly Mixed Portland Cement
Concrete”, ASTM International, West Conshohocken, 2003.
ASTM D 75, “Standard Practice for Sampling Aggregates”, ASTM International, West
Conshohocken, 2009.
ASTM D 1998, “Standard Specification for Polyethylene Upright Storage Tanks”, ASTM
ASTM E 11, “Standard Specification for Wire Cloth and Sieve for Testing Purposes”, ASTM
ASTM E 74, “Standard Practice of Calibration of Force-Measuring Instruments for Verifying The
Force Indication of Testing Machines”, ASTM International, West Conshohocken, 2006.
Kosmatka, Steven H.; Kerkhoff, Beatrix; and Panarese, William C., “Design and Control of
Concrete Mixture”, Portland Cement Association, Illinois, 2008.
PBI 1971, “Peraturan Beton Bertulang Indonesia”, Direktoran Penyelidikan Masalah Bangunan,
Bandung, 1971.
PD-T-04-2004-C, “Tata Cara Pembuatan dan Pelaksanaan Beton Berkekuatan Tinggi”,

Departement Permukiman dan Prasarana Wilayah, Jakarta, 2004.
SNI 7974:2013, “Spesifikasi Air Pencampur yang Digunakan dalam Produksi Beton Semen
Hidraulis”, Badan Standardisadi Nasional (BSN), Jakarta, 2013.
SNI-02-2834-2000, “Tata Cara Pembuatan Rencana Campuran Beton Normal”, Badan

Standardisadi Nasional (BSN), Jakarta, 2000.
SNI-03-1750-1990, “Agregat Beton, Mutu dan Cara Uji”, Badan Standardisadi Nasional (BSN),
Jakarta, 1990.
175
SNI-03-1753-1990, “Agregat Kasar untuk Beton, Cara Penentuan Butir Halus Lebih Kecil dari 70
Mikron”, Badan Standardisadi Nasional (BSN), Jakarta, 1990.
SNI-03-1968-1990, “Agregat Halus dan Kasar, Metode Pengujian Analisis Saringan”, Badan
SNI-03-1970-1990, “Metode Pengujian Berat Jenis dan Penyerapan Air Agregat Halus”, Badan
SNI-03-1974-1990, “Metode Pengujian Kuat Tekan Beton”, Badan Standardisadi Nasional (BSN),
Jakarta, 1990.
SNI-03-2460-1991, “Abu Terbang Sebagai Bahan Tambahan untuk Campuran Beton, Spefikasi”,
Badan Standardisadi Nasional (BSN), Jakarta, 1991.
SNI-03-2847-2002, “Tata Cara Perencanaan Struktur Beton untuk Bangunan Gedung”, Badan
SNI-03-4433-1997, “Spesifikasi Beton Siap Pakai”, Badan Standardisadi Nasional (BSN), Jakarta,
1997.
SNI-1969-2008, “Cara Uji Berat Jenis Penyerapan Air Agregat Kasar”, Badan Standardisadi
Nasional (BSN), Jakarta, 2008.
SNI-1972-2008, “Cara Uji Slump Beton”, Badan Standardisadi Nasional (BSN), Jakarta, 2008.
SNI-2458-2008, “Tata Cara Pengambilan Contoh Uji Beton Segar”, Badan Standardisadi Nasional
(BSN), Jakarta, 2008.
SNI-4810-2013, “Tata Cara Pembuatan dan Perawatan Spesimen Uji Beton di Lapangan”, Badan
176
APPENDIX
177
177
Doc. Code:
Standard Requirement for Concrete Raw Material QC-Concrete-STD-RQ01 R.00 201504
No Material Check Items Requirement Remarks

FINESESS MODULUS (FM) Max. 8 All the test shall be
CLAY CONTENT Max. 5% conducted with SHIMZ
MATERIAL FINER THAN NO.200 Max. 1% staff involvement (witness
COARSE AGGREGATE
SIEVE and sample taken) at the

time of pre-trial mix
(ASTM C33)
(1 1/2-in) 37.5-mm 100%

inspection prior to trial mix
(1-in) 25mm 95%-100% execution
1
(1/2-in) 12.5mm 25%-60%
(No. 4) 4.75mm 0%-10%
(No. 8) 2.36-mm 0%-5%
RELATIVE DENSITY (SPECIFIC >2.5
GRAVITY) OD
WATER ABSORBTION 4%
FINESESS MODULUS (FM) 2.3-3.1 All the test shall be
CLAY CONTENT Max.3% conducted with SHIMZ
MATERIAL FINER THAN NO.200 Max. 5% staff involvement (witness
SIEVE and sample taken) at the
time of pre-trial mix
(3/8-in) 9.5-mm 100%
FINE AGGREGATE
inspection prior to trial mix

(ASTM C33)
(No.4) 4.75-mm 95%-100%

execution
(No. 8) 2.36-mm 80%-100%
2
(No. 16) 1.18-mm 50%-85%
(No. 30) 600-mm 25%-60%
(No. 50) 300-mm 5%-30%
(No. 100) 150-mm 0-10%
RELATIVE DENSITY (SPECIFIC >2.5
GRAVITY) OD
WATER ABSORBTION Max. 4%
No Material Check Items Requirements Remarks
CHEMICAL REQUIREMENTS - Batching plant shall
MgO (max %) 6 report test result to SHIMZ
SO3 (max %) in monthly basis and in the
C3A ≤ 8% 3 time of pre-trial mix
C3A > 8% 3.5 inspection
- Shimizu shall conduct the
test in yearly basis on
Insoluble Residue (max %) 3
CEMENT (OPC Type 1)
independent lab.
(SNI 02-2834-2000)
Equivalent Alkalies, as 0.6

Na2O, etc. (max %)
3
Air Content (max %) 12
Autoclave expansion (max 0.8
%)
Time of Setting
Initial 45 minutes
Final max. 375 minutes
Strength (min)
3 days 125 (kg/cm2)
7 days 200 (kg/cm2)
28 days 280 (kg/cm2)
SiO2+Al2O3+Fe2O3 (min %) 70 report test result to SHIMZ
SO3 (max %) 5 in monthly basis and in the
Moisture Content (max %) 6 time of pre-trial mix
inspection
- Shimizu shall conduct the
Equivalent Alkalies, as 1.5 test in yearly basis on
Na2O, etc. (max %) independent lab.
(SNI 03-2460-1991)
Specific Surface* (test required for
FLY ASH
adjustment)
4
Finesess (max %) 34
7 days (min %) -
28 days (min %) 75
Water Req. (max %) 105
Autoclave expansion (max 0.8
%)
Desity (max variation %) 5
5
No Material Check Items Requirements Remarks
Chloride Cl, ppm report test result to SHIMZ
Pre-stressed 500 in yearly basis and in the
concrete/bridges time of pre-trial mix
(SNI 7974:2013) Other RC in moist 1000 inspection
environment - Shimizu shall conduct the
containing aluminum test in yearly basis on
WATER
5 embedment or independent lab. sample

dissimilar metals taken direct from cement
Sulfate as SO4, ppm 3000 supplier
Alkalies as 600
(Na2O+0,658K2O), ppm
PHYSICAL REQUIREMENTS Potable, no smell,
no color
DOSAGE - Batching plant shall
Trial Result Slump & Strength report admixture brochure
for designated and technical data to
dosage shall be SHIMZ prior to trial mix
confirm through execution
ADMIXTURE
trial test prior to

6 trial mix execution
Dimension of Dosage Table of admixture
dosage for batching
control used shall
be based on
volume (lt) not by
weight (kg)
Doc. Code:
Standard Requirement for Concrete Batching Plant Facilities QC-Concrete-STD-RQ02 R.00 201504
No FACILITIES Check Items Requirement

STOCK PILE
Compartments Fully separated, No contamination
Concrete floor or 30cm from bottom part material
shall not be used
SILOS
MATERIAL STOCK

Hooper Efficient discharge, not exceed allowable
1 tolerance,
Cement ±1%
Fly Ash ±1%
WATER TANK
To meet day-to-day needs (BP capacity of
Capacity production)
MOISTURE TEST
Total Moisture
Oven Ventilated oven. Capable to maintain
If use microwave oven, container shall be non-
metallic material. Temperature above 110oC
Frying Pan May be used for small quantity of testing, Use hot
plate
Surface Moisture
Flask; Glass or non-corrosive metal. Scale increment

2 pycnometer 0.5ml or less. Volume capacity shall be 2-3 times
sample volume.
SIEVE ANALYSIS
Coarse Aggregate
Sieve Number
Fine Aggregate
Sieve Number
CLAY CONTENT
Containers Anti-rust material
Drying Oven Ventilated oven. Capable to maintain
If use microwave oven, container shall be non-
metallic material
Relative Density (Specific
Gravity)
Balance Accurate to 0.05kg
Tamping Rod Dia.16mm, Length 600mm
Scoop Convenience with aggregates size
Plate Glass 6mm Thick, 25mm larger than measure diameter
WATER ABSORBTION
Balance Sensitivity 0.1gr or less,

2
capacity 1kg or more
Pycnometer/Flask Capacity ±100mm3, 50% more than samples
volume
Mold & Tamper Made of steel, Thickness 0.8mm, Inner top dia.
40±3mm, Inner bot dia. 90±3mm, Height 75±3mm
SLUMP TEST
Cone
Plate Thickness t1,5mm, good condition of flatness

Stick Diameter 16mm, length 600mm
TEMPERATURE
Thermometer Scale readable to 0.5oC increment throughout a
range of 0-50oC
SAMPLING
Cylinder
Stick Dia. 10±2mm, Length 300±100mm

No leakage, all specimen shall be fully cured
Pond under water
TEST
Machine Capacity of stress shall be more than designated
concrete strength,
Scales to return to zero
Apply load continuously without shock,
BINS
Separator Fully separated, No contamination, No overflow
to conveyor belt
signage to indicate usage of bins for every
Marking material type
Screen Mesh 100mmx100mm screen on top of bins

3 Hooper Efficient discharge, not exceed allowable
tolerance Agg. ±2%
CONVEYOR BELT Shall be free from other substance except
particular materials that being weight
WEIGHING CONTROL / Shall be calibrated once in 6 months,
SCALES Allowable tolerance:
Agg. ±2%; Cement/FA ±1%; water ±1%; Admixture
±3%
DISPENSER FOR ADMIXTURE Shall be separated for each of admixture type,
Shall be controlled flow (computerized)
Clear mark for scale
Start from zero while loading
WATER TANK Calibrated flow meter (computerized)

Thickness of wall shall be confirmed to hold water
pressure,
Free of contamination
MIXER Provided with acceptable timing device that will
3 not permit the batch to be discharge before the
specified mixing time has elapsed;
Volume capacity shall be 37% more than concrete
TRUCK MIXER
volume
Cleanliness shall be maintained
Mixing revolution 70-100
WEIGHING CONTROL /
CALIBRATION &
CERTIFICATION
SCALES once in 6 months, data to be submitted to SHIMZ

DISPENSER FOR ADMIXTURE annually, data to be submitted to SHIMZ
4 COMPRESSIVE STRENGTH
MACHINE annually, data to be submitted to SHIMZ
THERMOMETER annually, data to be submitted to SHIMZ
LABORATORY BALANCE once in 6 months, data to be submitted to SHIMZ
Doc. Code:
Standard Requirement for Concrete Batching Plant Process QC-Concrete-STD-RQ03 R.00 201504
No PROCESS Check Items Requirement Remarks

COARSE
AGGREGATE
MATERIAL DELIVERY CHECK
Visual Check Comply with master sample, No

discrepancy in color, shape and size
Clay Comply with specification mention
Content on '(BP)Raw Material' section
1
FINE AGGREGATE
Visual Check Comply with master sample, No
discrepancy in color, shape and size
Clay Comply with specification mention
Content on '(BP)Raw Material' section
MOISTURE
CONTENT
Total 2 times a day + after raining; Sampling method need to be
Moisture or confirmed (30cm from
Surface surface);
Moisture
SIEVE ANALYSIS Comply with specification mention Sampling shall be done and
on '(BP)Raw Material' section; test shall be witness by
REGULAR TESTING
Frequency: once a month; SHIMZ, taken 30cm from

No wash out, Done in dry condition surface (same place taken for
2 real batching);
Result shall be check
immediately and send to SC
JKT;
RELATIVE Comply with specification mention Sampling shall be done and
DENSITY on '(BP)Raw Material' section; test shall be witness by
(SPECIFIC Frequency once a month; SHIMZ, taken 30cm from
GRAVITY) Done both dry and SSD condition surface (same place taken for
real batching);
JKT;
No Process Check Items Requirements Remarks
WATER
ABSORBTION
Coarse Comply with specification mention Sampling shall be done and
Aggregate on '(BP)Raw Material' section; test shall be witness by
Frequency: once a month; SHIMZ, taken 30cm from
surface (same place taken for
real batching);
REGULAR TESTING

JKT;
Fine Comply with specification mention Sampling shall be done and
2 Aggregate on '(BP)Raw Material' section; test shall be witness by
Frequency: once a month SHIMZ, taken 30cm from
surface (same place taken for
real batching);
JKT;
FLY ASH Not more than 55mm; Test shall be witness by
SEDIMENT TEST Frequency: once a month; SHIMZ;
JKT;
WATER CONTENT Based on moisture content results, SHIMZ shall check adjustment
ADJUSTMENT every batch before batch
MATERIAL Addition of all ingredients shall be SHIMZ shall check material
ADDITION done in computerize system within input on batching time;
tolerance
Coarse ±2%
Aggregates
Fine ±2%
Aggregates
Cement ±1%
Fly Ash ±1%
BATCHING
Water ±1%
3
Admixture ±3%
MIXING
Timing Not less than 1.5 minutes for 1m3,
and additional 0.5 minutes for
every 1m3 volume addition
Concrete Capable of achieving a uniform
Condition distribution of the constituent
materials, and a uniform
consistence of the concrete
TRUCK LOADING No water inside before concrete SHIMZ should confirmed truck
loading condition before concrete
loading
No Process Check Items Requirements Remarks
Before delivery of every 7 truck
mixer
TEMPERATURE Max. 10oC above ambience temp.;
CHECK Complete temp. measurement
within 5 minutes after obtaining
the samples;
Before delivery of every 7 truck
mixer
SAMPLING
Procedure The elapsed time shall not be
exceed 15min after obtain the first
& final portions of sample
Cylinder 2 samples min for each purpose of
Numbers testing. (i.e. 2 for 7 days, 2 for 28
days, 2 for spare, etc.) for one set
of samples
Representati A set of samples represent 115m3
ve Amount volume or 465m2 surface, taken
AFTER BATCHING
from one truck mixer

SPECIMEN
4 CURING
Location Free from vibration and from direct
sun light
Temperature 23±2oC
COMPRESSIVE
STRENGTH
Preparation Machine gauge shall be at zero
Capping Shall be as followed: > 45 use gypsum capping
≤ 45 use sulfur capping
Placement Specimen shall be placed at the

center of machine
Doc. Code:
Standard Requirement for Concrete Mix Design QC-Concrete-STD-RQ04 R.00 201504
No. Items Requirement Tolerance

General <65%
Around 42 MPa ~57%

Max: +0,02% from design mix
1 W/C
Around 35 MPa ~ 48% (BS EN 206)
Around 28 MPa ~41%
2 Cement content Min. 300kg/m3

3 Water content Max 185lt/m3
4 S/A 45% ±3 %
5 Fine Aggregate No Manufacture Sand
6 Max. Coarse Agg. Size Max. Size 25mm
7 Admixture
Designated Clearly mention how many
Admixture liter admixture used
Designated Setting Clearly mention how many
Time hours setting time designated
Doc. Code:
Standard Requirement for Concrete Site Control & Monitoring QC-Concrete-STD-RQ05 R.00 201504
DELIVERY TICKET CHECK

Supplier To be mentioned on delivery ticket
Batching Plant To be mentioned on delivery ticket
Location
Delivery Ticket To be mentioned on delivery ticket
Number
Date To be mentioned on delivery ticket
Mixer truck no. To be mentioned on delivery ticket Supplier shall
attach batch
Project Information To be mentioned on delivery ticket
detail on
Concrete grade To be mentioned on delivery ticket
delivery time.
Cement Type Comply with mix design
Max. Aggregate Size To be mentioned on delivery ticket
Additional Ingredients To be mentioned on delivery ticket
Volume To be mentioned on delivery ticket
Slump design To be mentioned on delivery ticket
DELIVERY INSPECTION
Batch time To be mentioned on delivery ticket

Departure time To be mentioned on delivery ticket
1 every truck mixer
TEMPERATURE CHECK Max. 38oC;
Complete temp. measurement
within 5 minutes after obtaining the
samples;
Every truck mixer
SAMPLING
Procedure The elapsed time shall not be exceed
15min after obtain the first & final
portions of sample
Cylinder Numbers 2 samples min for each purpose of
testing. (i.e. 2 for 7 days, 2 for 28
days, 2 for spare, etc.) for one set of
samples
Representative A set of samples represent 115m3
Amount volume or 465m2 surface, taken
from 1 truck mixer
Sample Code Not allowed to do direct scratch on
top surface
Sticker put at top at first
SPECIMEN CURING
2 CURING Location Free from vibration and from direct
sun light
Disposal of Molding After 24H
Temperature 23±2oC
COMPRESSIVE
Independent 3rd party laboratory for

TEST
LABORATORY SELECTION
3 28 days
ACTUAL


Time
Batch To be clearly recorded
Departure To be clearly recorded
Arrival To be clearly recorded
Un-Loading To be clearly recorded;
Not more than designated initial setting
MONITORING
time
4 Finish To be clearly recorded
SUMMARY

Compressive Strength
Test Result
Others (as required)

No Time Check Items Requirements Remarks
TEMPERATURE CHECK
MASS CONCRETE
Thermocouple Confirmation and approval from BTD
Installation
5 Temperature Monitoring Confirmation and approval from BTD
METHOD OF STATEMENT
Casting Plan Confirmation and approval from BTD
SLAB
Method Water spray and plastic sheet
SITE CURING
Time Minimum for first 7 days

6 BIG COLUMN
Method Plastic cover/ Gani sack and water
spray
Time Minimum for first 7 days
COLUMN
FORMWORK
Without beam starter bar After 5 N/mm2

REMOVAL
7 With beam starter bar After 10 N/mm2
SUSPENDED BEAM & SLAB 100% design strength

SAW CUT
JOINT
8 SLAB ON GRADE Within 3 days after casting

Doc. Code:
Job Description of Concrete Person In Charge - Initial Stages QC-Concrete-STD-JD01 R.00 201504

1 Batching Plant
Checking
General Batching plant profile QC-Concrete-RCD-BP01 Pre-
Information Trial Mix
Facilities Checking on facilities condition QC-Concrete-RCD-BP04
Raw Checking on raw material condition QC-Concrete-RCD-BP03 Raw
Material through test report and actual check Material Check Sheet
comparison (on plant testing QC-Concrete-RCD-BP03-A
sampling & witness by SHIMZ) Fine Aggregate Analysis
QC-Concrete-RCD-BP03-B
Admixture Admixture supplier shall do trial QC-Concrete-RCD-BP01 Pre-
Dosage mixing to ensure the dosage and Trial Mix
Before Trial Mix
Confirmation inform to SHIMZ

Material Test at To send Fine and Coarse aggregate Actual 3rd party test result
Independent for material analysis (grading, FM,
Lab. SG, etc.)
Mix Design
Check
W/C Ratio >65%
Water <185 lt/m3
Cement >300 kg/m3 QC-Concrete-RCD-BP01 Pre-

Trial Mix
S/A Ratio 45±3%
Designated Clearly mention how many liter

Admixture admixture used
Designated Clearly mention how many hours
Setting Time setting time designated
2 Condition
Check
Conveyor Clean condition, no excess material QC-Concrete-RCD-BP02 Trial
Mix;
Batching Plant Check Photo
Trial Mix
Record
Truck Mixer No outstanding water inside QC-Concrete-RCD-BP02 Trial
Mix
Material Data Actual data for water adjustment: QC-Concrete-RCD-BP02 Trial
Fine agg. moisture content and Mix
water absorption
Mix Design To comply with requested concrete QC-Concrete-RCD-BP06 Mix
Check spec and grade Design Adjustment Sheet
2 Batch Check correction result after water QC-Concrete-RCD-BP06 Mix
Adjustment adjustment Design Adjustment Sheet
Check
Batching Check batching accuracy to meet the QC-Concrete-RCD-BP02 Trial
Process tolerance Mix
Trial Mix
Accuracy Check
Slump Lost & Monitor slump lost and temperature QC-Concrete-RCD-BP02 Trial
Temperature from fresh concrete condition, after Mix;
admixture addition until designated QC-Concrete-RCD-BP07
setting time Batching Plant Check Photo
Record
Salinity Check Actual result of salinity cannot be QC-Concrete-RCD-BP02 Trial
more than 0,3 kg/m3 Mix
Cylinder sample To provide cylinder sample in QC-Concrete-RCD-BP02 Trial
Provision sufficient method and numbers Mix
3 Strength Result Monitor actual strength achieved on QC-Concrete-RCD-BP02 Trial
After Trial Mix
Check 7 days and 28 days Mix;

Actual Compressive Test
Result
Doc. Code:
Job Description of Concrete Person In Charge - Cycles QC-Concrete-STD-JD02-A R.00 201504

1 Project Concrete Casting Detail plan on man power, QC-Concrete-RCD-PR01
Plan tools and equipment prior Casting Plan
to concrete casting time
Batching Condition Check
Plant Conveyor Clean condition, no excess QC-Concrete-RCD-BP05
material Actual Concrete
Monitoring;
Photo Record
Admixture Check zero level of QC-Concrete-RCD-BP05
Dispenser dispenser Actual Concrete
Before Concreting
Monitoring;
Photo Record
Truck numbers Enough truck numbers to QC-Concrete-RCD-BP05
deliver requested volume Actual Concrete
(based on casting plan) Monitoring
Material Data Actual data for water QC-Concrete-RCD-BP05
adjustment: Fine agg Actual Concrete
moisture content and water Monitoring
absorption; Fly Ash
Sediment Test
Mix Design Check To comply with requested QC-Concrete-RCD-BP06
concrete spec and grade Mix Design Adjustment
Sheet
Batch Adjustment Check correction result QC-Concrete-RCD-BP06
Check after water adjustment Mix Design Adjustment
Sheet
2 Batching Batching Process Check consistency of QC-Concrete-RCD-BP05
Plant Accuracy Check batching accuracy for the Actual Concrete
first 5 truck Monitoring;
During Concreting
Photo Record
Fresh Concrete Check consistency of slump QC-Concrete-RCD-BP05
Quality Check and temperature for the Actual Concrete
first 5 truck Monitoring;
Photo Record
2 Project Delivery Inspection Slump and Temperature to
be checked every truck
Cylinder Sample Truck monitoring, sample
During Concreting
Provision code control
Time Monitoring Truck to be monitored from QC-Concrete-RCD-PR02
arrival time until finished Actual Concrete
unloading Monitoring
Volume Cumulative volume to be
Monitoring monitored
Placed Concrete Location of placed concrete
Monitoring to be recorded
3 Project Cylinder Sample Monitor dismantle time, QC-Concrete-RCD-PR03
Monitoring code and curing Concrete Monitoring
Sheet
Curing Monitoring Monitor curing time for -
After Concreting
each casted structure

Concrete Strength Monitor compressive Actual Compressive Test
Monitoring strength result of concrete Result
cylinder sample QC-Concrete-RCD-PR03
Concrete Monitoring
Sheet
Structure Checking final result of QC-Concrete-RCD-PR04
Clearance concreting, repair defective Structure Clearance
Inspection record
Doc. Code:
Job Description of Concrete Person In Charge - Routine QC-Concrete-STD-JD02-B R.00 201504

Batching Batching Plant Review accuracy of QC-Concrete-RCD-BP08
Plant Process Inspection batching process as per Process Check Sheet
1 SHIMZ requirement
Material Testing QC-Concrete-RCD-BP03
Raw Material Check Sheet
Fine Aggregate FM; Clay Content; Sieve; QC-Concrete-RCD-BP03-A
SG; Water Absorption; Fine Aggregate Analysis
Sampling by SHIMZ
Coarse FM; Clay Content; Sieve; QC-Concrete-RCD-BP03-B
Aggregate SG; Water Absorption; Coarse Aggregate Analysis
Sampling by SHIMZ
Monthly
Raw Material QC-Concrete-RCD-BP03

Review Raw Material Check Sheet
Cement OPC Chemical Req.; Physical Actual test result from
Type 1 Req. supplier
Fly Ash Chemical Req.; Physical Actual test result from
Req. supplier
Admixture Chemical Req.; Physical Actual test result from
Req. supplier
Indepen Material Testing
dent Fly As Chemical Req.; Physical Test Report from Supplier
Lab. Req.
Cement Chemical Req.; Physical Test Report from Supplier
Req.
3-monthly
2 Batching Batching Plant Checking condition of QC-Concrete-RCD-BP04

Plant Facilities plant facilities Facilities Check Sheet
Inspection
3 Indepen Material Testing

6-monthly
dent Fine Aggregate FM; Clay Content; Sieve; Actual 3rd party lab report
Lab. SG; Water Absorption
Coarse FM; Clay Content; Sieve; Actual 3rd party lab report
Aggregate SG; Water Absorption
Indepen Water Chemical Req. Actual 3rd party lab report
Annually
dent
4 Cement Chemical Req.; Physical Actual 3rd party lab report
Lab.
Req.

Concrete Handbook - 1

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Concrete Handbook - 1

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FOR SHIMIZU INTERNAL USE ONLY.

ANY UNCONTROLLED COPYING, DISTRIBUTING

CONCRETE CONTROL &

REQUIREMENTS FOR SHIMIZU JAKARTA OFFICE

SC JKT CONCRETE COMMITTEE 2016

Concrete Readymix Readymix Readymix

2) Project Concrete Person in Charge

1.2 FLOW CHART

1.2.1 INITIAL STAGE

b) Trial Mix Execution

c) Trial Mix Result Review

a) Concrete Checking Cycle

b) Routine Test & Inspection

1.3.1 CONCRETE PRODUCTION

b) Concrete Control and Monitoring

Figure 1.1 Sample of Concrete Strength Monitoring

1.4 ACTIONS TOWARDS INSUFFICIENCY

No Material Check Items Requirement

(3/8-in) 9.5-mm 100&

(No.4) 4.75-mm 95%-100%

Insoluble Residue (max %) 3

Other RC in moist environment containing 1000

trial test prior to

2.2.1 Fine Aggregate

Figure 2.1 Quarry location and visual samples of Bangka sand

Figure 2.2 Quarry location and visual samples of Lampung sand

Figure 2.3 Quarry location and visual samples of Pontianak sand

Figure 2.4 Quarry location and visual samples of Ketapang sand

Table 2.4 Material Characteristic of Ketapang Sand

Figure 2.5 Quarry location and visual samples of Cimalaka sand

Figure 2.6 Quarry location and visual samples of Boyolali sand

Figure 2.7 Quarry location and visual samples of Weleri sand

Figure 2.9 Rumpin area location

Figure 2.10 Several Quarries in Rumpin

Figure 2.11 Visual appearances of Pion’s produced coarse aggregate

Specific Gravity Sample 1 Sample 2

Figure 2.12 Visual appearances of Kusumo’s produced coarse aggregate

¾ Batu Gunung Makmur (BGM)

Figure 2.13 Visual appearances of BGM’s produced coarse aggregate

Specific Gravity Sample 1 Sample 2

Figure 2.15 Visual appearances of Sudamanik’s produced coarse aggregate

Figure 2.16 Purwakarta area location

Figure 2.20 Jepara area location and Crusher at Calvary Quarry

2.2.3 Fly Ash

Figure 2.23 Suralaya power plant location map

Figure 2.24 Suralaya power plant chimneys

No FACILITIES Check Items Requirement

Plate Thickness t1,5mm, good condition of

Stick Dia. 10±2mm, Length 300±100mm

Screen Mesh 100mmx100mm screen on top of bins

BATCHING TOOLS & EQUIPMENT

DISPENSER FOR ADMIXTURE annually, data to be submitted to SHIMZ

No PROCESS Check Items Requirement

MATERIAL DELIVERY CHECK

Frequency once a month;

Fine Aggregate Comply with specification mention on '(BP)Raw

FLY ASH SEDIMENT TEST Not more than 55mm;

WATER CONTENT Based on moisture content results,

Fly Ash ±1%

Representative Amount A set of samples represent 115m3 volume or

Placement Specimen shall be placed at the center of machine

3.3.1 Adhimix in Jakarta Area

 Laboratory Facilities Information

Figure 3.2 Condition of Concrete Segregation

Laboratory Facilities Information

Laboratory Facilities Information

Laboratory Facilities Information

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