S-900-3120-001 - 2 - 0001 (Concreate Building)

DOC. No.
JOB No.
S-900-3120-001
0-5151-20
DATE
25
Rev.
FEB -
2009 SHEET
PREPD
K. Ishigami
CHKD
B.Li
APP'D
D. Tomonaga
2
1
OF
23
CONSTRUCTION SPECIFICATION
FOR
CONCRETE WORK
Donggi Senoro LNG Project
FOR CONSTRUCTION
REV.
Date
Page
DESCRIPTION
PRED
CHKD
APPD
25 Feb 2009
ALL
For Review
K. Ishigami
B.Li
D.Tomonaga
10 Aug 2011
ALL
For Construction
Y.Ishida
Y.Sato
D.Tomonaga
14 Oct 2011
For Construction (revised as marked)
Y.Ishida
Y.Sato
D.Tomonaga
DSLNG Project
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CONSTRUCTION SPECIFICATION FOR CONCRETE WORK
0-5151-20
S-900-3120-001 <Rev.2>
SHEET 2 OF 23
CONTENTS
CONSTRUCTION SPECIFICATION ...................................................................................................... 1

FOR ......................................................................................................................................................... 1
CONCRETE WORK................................................................................................................................1
DONGGI SENORO LNG PROJECT ...................................................................................................... 1
1
GENERAL........................................................................................................................................ 4
1.1
Scope ........................................................................................................................................ 4
1.2
Definitions ................................................................................................................................. 4
1.3
References................................................................................................................................4
1.3.1
Codes and Standards........................................................................................................ 4
1.3.2
Project Specifications and Drawings................................................................................. 5
1.4
Conflicts in Requirements......................................................................................................... 5
2.
INGREDIENTS OF CONCRETE ..................................................................................................... 5

2.1
Cement...................................................................................................................................... 5
2.1.1
Material Description........................................................................................................... 5
2.1.2
Storage .............................................................................................................................. 6
2.1.3
Rejection of Cement Material ............................................................................................ 6
2.2
Aggregates................................................................................................................................6
2.2.1
2.2.2
Storage .............................................................................................................................. 6
2.3
Mixing Water ............................................................................................................................. 6
2.4
Admixtures ................................................................................................................................6
2.4.1
2.4.2
Storage .............................................................................................................................. 7
2.4.3
Usage ................................................................................................................................7
3.
CONCRETE MIXING ....................................................................................................................... 8

3.1
Production by Batch Plant ........................................................................................................ 8
3.1.1
General Requirement ........................................................................................................ 8
3.1.2
Facility Requirements ........................................................................................................ 9
3.1.3
Measuring and Batching.................................................................................................... 9
3.2
Ready-Mixed Concrete ...........................................................................................................10
3.3
Production by In-Situ Concrete Mixer.....................................................................................10
3.4
Durability .................................................................................................................................10
3.5
Slump ......................................................................................................................................11
3.6
Air Contents ............................................................................................................................11
4.
REINFORCEMENT........................................................................................................................11
4.1
Materials..................................................................................................................................11
4.2
Fabrication and Placing of Rebars .........................................................................................11
4.2.1
General ............................................................................................................................11
4.2.2
Fabrication .......................................................................................................................11
4.2.3
Placing of Rebars ............................................................................................................12
4.2.4
Mechanical Splices..........................................................................................................12
CONCRETING ...............................................................................................................................12
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5.1
Blinding Concrete....................................................................................................................12
5.2
Formwork ................................................................................................................................12
5.2.1
General ............................................................................................................................12
5.2.2
Design and Installation of Formwork...............................................................................12
5.2.3
Preparation of Form Surface ...........................................................................................13
5.2.4
Removal of Forms ...........................................................................................................13
5.3
Anchor Bolts and Embedded Items........................................................................................14
5.4
Waterstops..............................................................................................................................14
5.5
Joints.......................................................................................................................................14
5.5.1
Construction Joints ..........................................................................................................14
5.5.2
Expansion Joints .............................................................................................................15
5.5.3
Contraction Joints............................................................................................................15
5.6
Placing of Concrete ................................................................................................................15
5.6.1
Transportation .................................................................................................................15
5.6.2
Placing .............................................................................................................................15
5.7
Finishing..................................................................................................................................16
5.8
Curing......................................................................................................................................17
5.8.1
General ............................................................................................................................17
5.8.2
Moisture Retention ..........................................................................................................17
5.8.3
Protection from Mechanical Injury...................................................................................17
6.
REPAIR OF SURFACE DEFECTS ...............................................................................................17
7.
HOT WEATHER CONCRETE.......................................................................................................18
8.
MASS CONCRETE........................................................................................................................18
9.
PRECASTING FOR CATCH BASINS, MANHOLES, PITS, AND OTHER FOUNDATIONS......19
10.
INSPECTION AND TEST ..........................................................................................................19
10.1 Construction Tolerance...........................................................................................................19

10.1.1 General ............................................................................................................................19
10.1.2 Concrete ..........................................................................................................................19
10.1.3 Reinforcement .................................................................................................................20
10.1.4 Anchor Bolts & Embedded Items ....................................................................................21
TABLE-5: TOLERANCE OF ANCHOR BOLT GROUPS....................................................................21
TABLE-6: TOLERANCE FOR EMBEDDED ITEMS............................................................................21
10.2 Inspection and Test ................................................................................................................21
10.2.1 General ............................................................................................................................21
10.2.2 Sampling for Test ............................................................................................................21
10.2.3 Slump Test.......................................................................................................................21
10.2.4 Compressive Strength Test.............................................................................................22
10.2.5 Water Filling Test for Concrete Ponds/Pits .....................................................................22
10.3 Test Reports ...........................................................................................................................23
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GENERAL
1.1
Scope
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This specification describes the construction requirements for Concrete Works, including
materials, proportioning, mixing, placing, testing and curing of plain and reinforced concrete
for Donggi Senoro LNG Project, Indonesia.
ACI 301-05, Specifications for Structural Concrete, shall be applied as the general
specification for concrete supply and construction, except as specified herein or elsewhere
in the Contract Documents.
1.2
Definitions
The following terminologies are used in this specification.
(1) The OWNER is PT. Donggi-Senoro LNG
(2) The CONTRACTOR is PT. JGC Indonesia and JGC Corporation Consortium.
(3) The SUBCONTRACTOR is the party appointed by CONTRACTOR which carries out
the activities of the Work.
1.3
References
1.3.1
Codes and Standards

ACI American Concrete Institute
117/117R
Standard Specifications for Tolerances for Concrete Construction and

Materials
211.1
Standard Practice for Selecting Proportions for Normal, Heavyweight, and

Mass Concrete
301
Specification for Structural Concrete
302.1R
Guide for Concrete Floor and Slab Construction
304R
Guide for Measuring, Mixing, Transporting, and Placing Concrete
304.2R
Placing Concrete by Pumping Methods
305R
Hot Weather Concreting
308/308R
Standard Practice for Curing Concrete
318
Building Code Requirements for Structural Concrete
347R
Guide to Formwork for Concrete
350
Code Requirements for Environmental Engineering Concrete Structures

and Commentary
504R
Guide to Joint Sealants for Concrete Structures
SP2
ACI Manual of Concrete Inspection
SP17
ACI Design Handbook
SP-66
ACI Detailing Manual
SP-78
Foundation for Equipment and Machinery
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ASTM
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American Standards for Test and Materials
A185/A185M
Standard Specification for Steel Welded Wire Fabric, Plain, for

Concrete Reinforcement
Standard Specification for Carbon Steel Bolts and Studs
A307
A615/A615M
Standard Specification for Deformed and Plain Billet-Steel Bars for

Concrete Reinforcement
C31
Standard Practice for Making and Curing Concrete Test Specimens in
the Field
C39
Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
C94/C94M
Standard Specification for Ready Mixed Concrete
C143/C143M Standard Test Method for Slump of Hydraulic-Cement Concrete
C150/C150M Standard Specification for Portland Cement
C172/C172M Standard Practice for Sampling Freshly Mixed Concrete
And other standards and specifications related to works described hereinafter.
1.3.2
Project Specifications and Drawings

S-900-1358-015
Application for Grouting of Rotating Equipment
D-900-1310-001 Standard Drawing for Civil General Notes

D-900-1320-001 Standard Drawing for Hooks, Development Length and Splice of Rebar
D-900-1320-002 Standard Drawing for Anchor Bolts
D-900-1320-011 Standard Drawing for Rebar Arrangement (1/2)
D-900-1320-012 Standard Drawing for Rebar Arrangement (2/2)
1.4
Conflicts in Requirements
Conflicts among different codes and standards as well as project specifications and
drawings shall be notified to OWNER/CONTRACTOR for resolution. However, in the event
of conflicts, order of priority shall be as follows:
1. Design drawings
2. Standard drawings and specifications
3. International codes and standards as ACI, ASCE, ASTM, etc.
2.
INGREDIENTS OF CONCRETE
2.1
Cement
2.1.1
Material Description
Cement shall conform to Ordinary Portland Cement ASTM C150 Type I, Blended Hydraulic
Cements ASTM C595 or Portland Composite Cement SNI 15-7064-2004, unless otherwise
specified.
Manufacturers Test Certificate shall be submitted to OWNER/CONTRACTOR for each
delivery.
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Storage
Cement shall be stored in weather-tight sheds, bins or silos which will provide protection
from moisture and contamination. Cement bags shall be stored at a height of minimum 0.3m
above floor that shall be concrete paved.
Consignment of cement shall be stored as received and shall be consumed in the order of
delivery.
2.1.3
Rejection of Cement Material

Cement remaining in weather-tight bulk storage for more than 6 months, or cement in bags
in local storage in the custody of a vendor for more than 3 months after completion of tests
shall not be used. Cement that has become caked or partially set also shall not be used.
2.2
Aggregates
2.2.1
Both Fine and Coarse Aggregate shall meet the requirements of ASTM C33. Fine Aggregate
shall consist of clean, washed, natural or crushed sand of uniform gradation. Coarse
Aggregate shall consist of washed gravels or washed crushed stones that are hard, strong,
durable, and free from adherent coating, other weak and deleterious substances.
Maximum size of coarse aggregate for structural concrete shall be 20 mm, except that
fireproofing concrete that shall be 10 mm.
The source of materials shall be approved by OWNER/CONTRACTOR, and not be changed
without OWNER/CONTRACTORs approval.
2.2.2
Storage
Aggregate stockpiles shall be arranged and used in a manner to avoid excessive
segregation and to prevent contamination with other materials or with other sizes of similar
aggregates. To ensure that this condition is met, test for determining conformance to
requirements for cleanness and grading shall be performed on samples secured from the
aggregates at the point of batching. The stockpiles shall be kept to have uniform moisture
content throughout the stockpile.
2.3
Mixing Water
Mixing water for concrete shall meet the requirements of ASTM C94 and ASTM
C1602/C1602M and free from injurious amounts of oil, acid, salt, alkali, organic matter, and
other deleterious substances. Seawater shall not be used for mixing concrete.
Water shall have a pH between 6.0 and 8.0.
2.4
Admixtures
2.4.1
Admixtures shall conform to the requirements given in ACI 212.3R, 212.4R, ASTM C260,
ASTM C494, ASTM C618 or ASTM C1017 and shall not contain chloride nor any corrosive
agents.
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Storage
Admixtures shall be stored in a manner that will avoid contamination, evaporation, or
damage, conforming to the recommendations and instructions given by the manufacturer.
2.4.3
Usage
Careful attention should be given to the manufacturers instruction.
When more than one admixture is used, the combination of such admixtures shall not have
any harmful effects on the concrete. SUBCONTRACTOR shall submit written statement to
prove no harmful effects and test of trial mixtures prior to the commencement of work.
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3.
CONCRETE MIXING
Requirements for concrete are summarized in the following Table,
Specified
Compressive
Strength
Items
Maximum
Water
Cement
Ratio
(MPa)
Maximum
Coarse
Aggregate
Slump
Air
Contents
(mm)
(mm)
Beams, Columns, Walls

Foundations Walls and
Footings, Duct Banks,
Sleepers, Culverts,
Pavements, Floors and
Slabs
Watertight concrete
28
0.50
20
10025
3.51.5
28
0.50
20
7525
3.51.5
28
0.45
20
7525
3.51.5
Exposed to sea water
28
0.40
20
7525
3.51.5
Lean Concrete
10
0.60
20
7525
3.51.5
Fireproofing Concrete
21
0.50
10
7525
3.51.5
3.1
Production by Batch Plant
3.1.1
General Requirement
The plant shall have functions capable for continuous concrete supply and for testing
requested in the specifications during construction work. The plant shall be located within
the plant fence. This batch plant is installed as a temporary facility, thus, all facility shall be
removed and cleared after the construction work is completed.
The batch plant and associated facilities shall include, but not limited to:
Batching and mixing units

Aggregate bins/weighing hopper
Cement weighing hopper
Cement silos
Operator cabin
Conveyors
Water chilling system
Insulated water storage tanks and water pump.
Cement & admixture storage warehouse
Aggregate storage bins/shelters/yard
Laboratory and office with toilet
Curing pool for compression test cylinder
Washing basin for truck mixers
Drainage facilities including siltation pits.
Generator with electrical distribution system
Mixer trucks
Lighting system
SUBCONTRACTOR shall submit his complete plan to meet the requirement herein and
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hereunder for OWNER/CONTRACTORs approval before commencing related works.

3.1.2
Facility Requirements
(1) The batch plant shall be a full-automated wet mixing type, and be designed to have
capacity to produce the appropriate and sufficient quantity of concrete. The capacity of
batch plant shall fulfill maximum construction requirement. At least two batch plants or
mixers shall be installed for a back-up purpose.
(2) The batch plant should be painted white to reflect the sun and be directly shaded from
the sun.
(3) Aggregate storage bins shall have partitions to separate fine and coarse aggregate and
different size/type of aggregate. The floor of the bins shall be concrete to prevent
contamination with soils. The storage bins shall have roofs for sunshade and equipped
with water spray system.
(4) The cement silos shall be an adequate size to store sufficient cement to ensure
continuity of work. The silos shall be equipped with thermometers to check temperature
of cement. Ventilation system shall be provided for cement storage.
(5) The laboratory shall have equipment for the field testing of concrete and concrete
materials.
(6) Temporary drainage system including siltation pits shall be provided and drains from the
batch plant area shall be treated prior to discharge to the surface water drainage
system.
3.1.3
Measuring and Batching

(1) Concrete Production
The weighing and mixing shall be a fully automated.
Quality of concrete produced in the plant shall meet the standard stipulated in relevant
Project specification including:
- Material for concrete: cements, admixtures, mixing water, aggregates.
- Proportioning: concrete strength, durability, slump, maximum size of coarse
aggregate, determination of standard deviation.
- Production of concrete: temperature control of concrete materials including mixing
water and weather conditions.
(2) Accuracy of Scales
The accuracy of weighing scales shall be within 0.4 percent of their total capacities.
Standard test weights shall be kept available on site for checking the accuracy of all
scales.
(3) Accuracy of Batching
Batching equipment shall be operated within the tolerances conforming to ACI 304 R.
(4) Mixing
The concrete shall be mixed in a batch mixer capable of thoroughly combining the
aggregates, cement, and water into a uniform mass within the specified mixing time,
and of discharging the concrete without harmful segregation.
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(5) Control of Admixtures

Separate containers and measuring devices shall be used for admixtures. Admixtures
shall be charged into the mixer as solutions. The liquid shall be considered a part of the
mixing water. Admixtures that cannot be added in solution may be weighed or
measured by volume if so recommended by the manufacturer. If two or more
admixtures are used in the concrete, they shall be added separately to avoid possible
interaction that might interfere with the efficiency of either admixture or adversely affect
the concrete.
(6) Calibration
All laboratory equipment and batch plant equipment shall be calibrated regularly in
accordance with Indonesian Regulation and ACI 304R.
3.2
Ready-Mixed Concrete
When ready-mixed concrete is to be used, requirements of ASTM C94/C94M shall be
satisfied.
Subject to OWNER/CONTRACTORs approval, truck-mixing may be allowed for dry
batching, where all mix ingredients are pre-batched in a batch plant. Water and liquid
admixtures are added at site. In this case, discharge of the concrete shall be achieved within
90 minutes after introduction of the mixing water to the cement and aggregates, and before
the drum of the truck has revolved 300 revolutions. Each truck delivering concrete shall have
an operable water system with an accurate water measuring device of one of the following
types:
- automatic cut off siphon type
- water meter of the automatic shut off type
- sight gage
The final concrete shall satisfy the requirements of this specification. Consistency and
uniformity tests shall be performed as per the requirements of ASTM C94/C94M. Test shall
be witnessed by representative from OWNER/CONTRACTOR.
3.3
Production by In-Situ Concrete Mixer

In-Situ Concrete Mixer may be used for concreting work for small items that can be
completed with one batch.
In-Situ Concrete Mixer shall not be used without OWNER/CONTRACTORs approval.
3.4
Durability
(1) Normal weight concrete shall have a maximum water cement ratio of 0.50 for structural
concrete including fireproofing concrete, and 0.60 for non-structural concrete.
(2) Normal weight concrete required being watertight shall have a water-cement ratio not
exceeding 0.45 if exposed to fresh water, or 0.40 if exposed to seawater.
(3) The maximum concentration of water soluble chloride ions (Cl-) accumulated in the
concrete by all of the ingredients including water, aggregates, cement and admixtures
shall not exceed the values (percent by weight of cement) stipulated in ACI 318, Table
4.4.1.
(4) The total water-soluble sulfate content of the concrete mix expressed as SO3 should not
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exceed 4% by mass of the cement in the mix and ACI 318 requirement.
3.5
Slump
ACI 211.1 shall be referred for recommended slumps for various types of construction. The
slump shall be determined in accordance with ASTM C143. Unless otherwise specified, the
following slumps shall apply.
Slabs, beams, columns and walls
: 100mm25mm
Foundations walls, footings, slabs, etc
: 75mm25mm
Fireproofing concrete
: 75mm25mm
The slump ranges shown apply when vibration is used to consolidate the concrete. The
slumps may be increased 25mm for method of consolidation other than vibration.
Slump may be increased when chemical admixtures are used, provided that the
admixture-treated concrete has the same or lower water-cement or water-cementitious
material ratio and does not exhibit segregation potential or excessive bleeding.
3.6
Air Contents
Air content tests shall be in accordance with the requirements of either ASTM C138 or C173,
or C231.
4.
REINFORCEMENT
4.1
Materials
Steel reinforcement shall conform to the requirements of SNI-07-2052-2002 Grade BJTS40,
yield strength fy=390 N/mm 2, or ASTM A615 Grade 60 or equivalent. Steel welded wire
fabric shall conform to the requirements of SNI 07-0663-1995, ASTM A185 or equivalent.
Reinforcement shall satisfy the followings as per Section 21.2.5 of ACI 318:
(a) The actual yield strength based on mill tests does not exceed the specified yield strength
by more than 120MPa (retests shall not exceed this value by more than an additional
20MPa); and
(b) The ratio of the actual ultimate tensile strength to the actual tensile yield strength is not
less than 1.25.
4.2
Fabrication and Placing of Rebars
4.2.1
General
Details of concrete reinforcement and accessories not covered herein shall be in
accordance with ACI 315.
4.2.2
Fabrication
(1) Welding of reinforcing bar shall be avoided.
(2) General construction details and workmanship relative to reinforcement, including bar
bends, lap splices and installation shall be in accordance with ACI 318, Chapters 7 and
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12. Unless otherwise noted, all lap splices of deformed bars and deformed wire in
tension shall be Class B.
4.2.3
Placing of Rebars
(1) Reinforcing bars shall be free from mud, dirt, loose rust, loose mill scale, oil, grease, and
any other foreign matter that may reduce the bond between bars and concrete.
(2) All reinforcement shall be supported and fastened together to prevent displacement
beyond the required tolerances due to construction loads or the placing of concrete.
Reinforcing bars shall be supported by pre-cast concrete/mortar blocks having a
compressive strength not less than the specified compressive strength of the concrete,
or by other acceptable spacers made of metal, plastic, etc.
(3) Splices in reinforcement shall be made and located as required by design drawings, in
the construction notes, or as otherwise approved. Splices in adjacent bars shall be
staggered.
(4) Lap splices shall not be used at the following locations as per ACI 318 Para.21.5.2.3.
(a) within the joints
(b) within a distance of twice the member depth from the face of the joints
4.2.4
Mechanical Splices
Mechanical splices shall be Type 2 conforming to ACI 318 Sec.21.1.6.1 (b).
Mechanical splices of beam reinforcement shall be located not closer than half of the beam
height from the joint face. Splice sleeves, filling mortar and all other associated materials
shall be installed in accordance with manufacturers instructions and manuals.
CONCRETING
5.1
Blinding Concrete
All reinforced concrete foundations shall be constructed on plain concrete blinding. Minimum
thickness of blinding shall be 50 mm, and it shall be extended to at least 50 mm outside the
foundation perimeters in all directions.
5.2
Formwork
5.2.1
General
(1) Requirements for formwork not covered herein shall be in accordance with ACI 347R.
(2) Forms shall have sufficient strength to withstand the pressure resulting from placement
of concrete and vibration during concrete pouring, and shall have sufficient rigidity to
meet specified tolerances.
(3) The forms material shall produce smooth, hard and uniform texture on the concrete
surface unless different texture requirement shown on the drawings.
5.2.2
Design and Installation of Formwork

(1) Forms shall be sufficiently tight to prevent loss of mortar from the concrete. Chamfer
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strips shall be placed in the corners of forms to produce 25 mm chamfer beveled edges
on permanently exposed surfaces. Chamfer strips are not required on interior corners
for edges of formed joints, tops of piers supporting horizontal vessels, and concrete
edges providing direct support for flooring, or to which steel will be attached for flooring
support.
(2) Temporary openings shall be provided at the base of column forms and wall forms and
at other points where necessary to facilitate cleaning and inspection immediately prior to
concreting.
(3) Positive means of adjustment (wedges, jacks, etc.) of shores and struts shall be
provided and all settlement shall be taken up during concrete placing operation. Forms
shall be securely braced against lateral deflections.
(4) Earth cuts shall not be used as forms for lateral surfaces unless required or permitted.
5.2.3
Preparation of Form Surface

(1) All surfaces of forms and embedded materials shall be cleaned of all accumulated
mortar or grout from previous concreting and of all other foreign material before
concrete is placed.
(2) Before placing the reinforcing steel or the concrete, the surfaces of the forms shall be
covered with an acceptable coating material that will effectively prevent absorption of
moisture, prevent bond with the concrete, and not stain the concrete surfaces. A field
applied form release agent or sealer of acceptable type or factory applied
non-absorptive liner may be used. Care shall be taken that the parting agent does not
get on concrete or reinforcement, which is to bond with new concrete.
5.2.4
Removal of Forms
(1) Removal of forms and supports shall be in accordance with ACI 347.
(2) When repair of surface defects or finishing is required at an early age, forms shall be
removed as soon as the concrete has hardened sufficiently to sustain the load and
resist damage from removal operations.
(3) Formwork for columns, walls, sides of beams and other parts not supporting the weight
of the concrete may be removed as soon as the concrete has hardened sufficiently to
resist damage from removal operations.
Forms and shoring in the formwork used to support the weight of concrete in beams,
slabs and other structural members shall remain in place until the concrete has reached
the required strength to support the weight of concrete and anticipated imposed loads.
Field-cured specimens shall be used to estimate the strength of concrete. When fieldcured specimens can not be used to determine the time of the form removal, forms and
shoring shall be remain in place for a period of time not less than that specified in ACI
347R.
Walls
:12 hours (Note 1)
Columns and Pedestals
:12 hours (Note 1)
Sides of Beams, Girders and Footings
:12 hours (Note 1)
Joist, Beam or Girder Soffits:

- Beams perpendicular to piperacks
or equipment supporting structures
:14 days (Note 2, 3)
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:21 days (Note 2, 3)
Note 1: Where such support formwork for slab or beam soffits, the removal times of the
latter should govern.
Note 2: In the case when design strength of concrete is confirmed by crushing test at 7
days, formworks may be removed.
Note 3: Where forms may be removed without disturbing shores, use half values shown.
(4) When forms are removed before the end of the required curing period, the concrete shall
be cured after removal of the forms by suitable methods.
5.3
Anchor Bolts and Embedded Items

(1) All sleeves, inserts, anchors and embedded items shall be placed and properly fixed
prior to concrete pouring. Voids in those embedded items shall be filled temporarily with
readily removable material to prevent the entry of concrete into the voids.
(2) Anchor bolts and other embedded items shall be cleaned of undesirable coatings, such
as scale, grease, or dirt that would be detrimental to bonding with concrete.
(3) Anchor bolts shall be placed inside the "cages" of reinforcing bars.
(4) Other embedded items shall be installed as shown on design drawings and they shall be
supported against displacement during placement and consolidation of concrete.
(5) Top of anchor bolt sleeves, if any, shall be cut off flush with rough concrete just prior to
grout or equipment installation.
(6) Embedded plates shall be flush with concrete surface, and shall be visible after forms
are removed.
5.4
Waterstops
PVC water-stop shall be used. (Minimum width 150mm unless noted otherwise).
The location of water-stops in joints shall be in accordance with the construction drawings.
Water-stops shall be installed per ACI 301, Section 2.2.
5.5
Joints
5.5.1
Construction Joints
(1) Construction joints shall be made as shown on the drawings and per ACI 301.
Construction Joints not indicated on the construction drawings may be provide at
SUBCONTRACTOR's option, except that they must meet the requirements of ACI 301.
Joints shall be perpendicular to the main reinforcement.
(2) Construction joints shall not be made in horizontal framing members unless called for on
the drawings. Construction joints in elevated slabs should be located preferably wihtin
middle third of the span between adjacent supporting members.
(3) The surface of the concrete at all joints shall be rough, thoroughly cleaned and all
laitance shall be removed prior to placing adjoining concrete. The laitance shall be
removed by brushing, chipping, wet sandblasting or high pressure water-blasting down
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to sound mortar matrix, leaving clean, sound aggregate exposed over the entire joint
surface, but not undercutting the large aggregate particles. The surface of the concrete
shall then be washed thoroughly to remove all loose material.
(4) All concrete joint surfaces to receive new concrete shall be free of surface water but
shall be in a saturated surface dry condition. Construction joints of which strength is
critical against shear, or which requires water-tightness should be covered with 12mm
mortar immediately before the concrete placing, or provided with keys having 1/3 width
of the smallest joined member and 50mm depth.
5.5.2
Expansion Joints
Expansion joints shall be made as shown on the drawings and per ACI 301.
Expansion joints shall extend to the full width and depth of the concrete section.
Expansion joint filler material shall conform to ASTM D994 or ASTM D1751.
5.5.3
Contraction Joints
Contraction Joint shall be made straight and uniform by forming, tooling or sawing. The
sealer material and their application shall confirm to ASTM D2628.
5.6
Placing of Concrete
5.6.1
Transportation
(1) Concrete shall be transported from Batch Plant to the construction site by methods
which prevent segregation, loss, or contamination of concrete ingredients so as to
assure that the required quality of the concrete is maintained.
(2) A time for transportation from the time of adding cement till the final pouring shall not
exceed good concrete setting time determined during trial mixing
(3) Aluminum and aluminum alloy material shall not be used in conveying equipment,
including trucks, pump lines, tremies, chutes, etc. Short pump lines, tremies and chutes
to remove concrete from transit truck mixers are excluded.
5.6.2
Placing
(1) Hardened concrete parts and foreign materials shall be removed from the inner surfaces
of the conveying equipment.
(2) All below ground concrete should be placed on a layer of blinding concrete. In dry
weather, any soil on which concrete is to be placed shall be moistened immediately
before placing the concrete. Concrete shall not be placed in standing water.
(3) Prior to placing concrete the reinforcement shall be secured in place, the embedded
items shall be positioned and the interior of all forms shall be thoroughly cleaned and
made free from all foreign matter and accumulated water. The interior of wooden forms
shall be wetted prior to concrete placing. The entire preparation shall be accepted by
OWNER/CONTRACTOR.
(4) To minimize segregation, the concrete shall be deposited at a position as near as
possible to its final position.
(5) The placement rate shall be such that the concrete will remain plastic at all times, and
will flow readily into all spaces between the reinforcing bars, etc.
(6) Concrete that has partially hardened or has been contaminated by foreign matter shall
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not be used.
(7) Once placement has started, it must be carried out continuously until the placing of the
concrete for that panel or section is completed.
(8) The drop height for the concrete shall not exceed 1.5 meters. Temporary openings shall
be provided for tall forms to reduce the drop height and to enable easy vibration. To
ensure sufficient vibration, concrete shall be placed in horizontal layers not exceeding
0.6 m in depth; care must be taken to ensure that the top surface of each layer is
horizontal.
(9) Unless otherwise specified, all concrete shall be thoroughly consolidated by vibrators
during placing. The vibrators shall be inserted in a vertical direction into the concrete,
and care shall be taken to ensure that the concrete is thoroughly worked around the
reinforcement, anchor bolts and other embedded fixtures, and into the comers of the
forms. A proper number of spare vibrators shall always be kept at the site during all
concrete placing operations. Vibration equipment shall not be used to move concrete
within the forms.
(10) Concrete placing for large or lengthy foundations and structures shall be so performed
as to avoid cold joints.
(11) Concrete shall not be placed during rain unless the adequate protection of the concrete
is provided until it has hardened sufficiently so that it will not be damaged and the
acceptance from OWNER/CONTRACTOR is obtained.
5.7
Finishing
(1) All finished concrete shall be as stated below, unless otherwise specified elsewhere in
the drawings. The specified surface finish and correlating tolerance requirements shall
be as defined in ACI 301, unless noted otherwise.
(2) Equipment bases shall be finished with a floated finish. Float finish shall be provided by
screeding to the required level with a straight edge and finished with a hand float, a
bladed power float equipped with float shoes, or a powered disk float.
(3) Interior floor slabs shall be finished with a trowel finish. Trowel finish shall be finished by
tamping the concrete with a wire mesh tamper to depress the coarse aggregate
sufficiently to bring the matrix fines to the surface, then screeding and striking with
straight edges to bring the surface to the required finished level. While the concrete is
still green, but sufficiently hardened to bear a man's weight without excessive imprint, it
shall be floated either by hand or mechanical means to a true, even plane, with no
coarse aggregate visible. Sufficient pressure shall be used on the float to bring
moisture to the surface. After surface moisture has disappeared, the surface shall be
machine or hand troweled to a smooth, even finish.
(4) Heavy broomed finish for vehicular traffic is to have a float finish, followed by brooming
with a heavy broom, producing patterns perpendicular to traffic.
(5) Surfaces designated for foot traffic are to receive a light broomed finish. They are to
receive a steel trowel finish, followed by brooming after completion of the troweling with
a horsehair bristle brush or light broom in a direction perpendicular to the main line of
traffic.
(6) Unless otherwise specified on drawings, top surfaces of concrete foundations on which
grout will be installed shall be rough-finished to an elevation of 25 mm to 50 mm below
finished elevation.
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5.8
Curing
5.8.1
General
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(1) Requirements for curing and protection of concrete not covered herein shall be in
accordance with ACI 308.
(2) Beginning immediately after placement, concrete shall be protected from premature
drying, excessively hot temperatures, and mechanical injury, and shall be maintained
with minimal moisture loss at a relatively constant temperature for the period necessary
for hydration of the cement and hardening of the concrete.
5.8.2
Moisture Retention
(1) For concrete surfaces not in contact with forms, one of the following procedures shall be
applied immediately after completion of placement and finishing:
Ponding or continuous sprinkling.
Application of absorptive mats or fabric kept continuously wet.
Application of sand kept continuously wet.
Application of sheet materials conforming to ASTM C171. The sheets shall be lapped
not less than 100 mm at edges and ends and be sealed with adhesive or pressure
sensitive tape no less than 40 mm in width. The membrane shall be weighted to
prevent displacement. Holes appearing in the membrane during curing period shall
be immediately patched. The membrane shall remain intact for not less than the
curing period in 5.8.2(3).
Application of other acceptable moisture-retaining covering.
Application of a curing compound conforming to ASTM C309.
The curing water used in the above methods shall be clean and free of contaminating
substances that will discolor the concrete.
(2) Moisture loss from surfaces placed against wooden forms or metal forms exposed to
heating by the sun shall be minimized by keeping the forms wet until they can be safely
removed. After form removal the concrete shall be cured until the end of the time
prescribed in Section 5.8.2 (3) by one of the methods of Section 5.8.2 (1).
(3) Curing in accordance with this section shall be continued for at least 7 days in the case
of all concrete except high-early-strength concrete, for which the period shall be at least
3 days.
(4) Abrupt changes in the temperature of the concrete shall be prevented.
5.8.3
Protection from Mechanical Injury

The concrete shall be protected from damaging mechanical disturbances, such as load
stresses, heavy shock, and excessive vibration. All finished concrete surfaces shall be
protected from damage by construction equipment, materials, or methods, by application of
curing procedures, and by rain or running water. Self-supporting structures shall not be
loaded in such a way as to overstress the concrete.
6.
REPAIR OF SURFACE DEFECTS

(1) Defects of concrete such as honeycombs, cracking or other conditions that are
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detrimental to strength, stability, durability and water tightness of the concrete shall be
repaired immediately after form removal per ACI 301 Section 5.3.7 or by approved
repair procedure. All defects shall be removed down to a sound surface. Curing
procedures shall not be delayed or interrupted while making repairs. Prior to repair of
defects, it shall be notified to OWNER/CONTRACTOR.
(2) Holes left by the withdrawal of tie-rods shall be filled solid with cement mortar and the
ends made flush with the surrounding surface area. It is recommended to refrain from
using hole-through tie rods for liquid retaining structures.
7.
HOT WEATHER CONCRETE

Concrete work is significantly affected by high temperatures in the concrete and in the air, or
by a low relative humidity, or by a high wind velocity. If these conditions are prevalent, the
concrete work shall be carried out in accordance with the requirements of ACI 305R, and the
following:
Where the concrete temperature exceeds 32 C, necessary preventive measures, as noted
below, shall be taken. However, if the rate of evaporation from the concrete surface as
determined by ACI 305R is less than 1.0 kgf/m 2/h that no preventive measures are required
even when the concrete temperature exceeds 32 C. In no case shall the concrete
temperature exceed 38 C. Exceeding the limiting water-cement ratio in order to have
sufficient slump for placing at concrete temperatures between 32 C and 38 C shall not be
permitted. Instead, the preventive measures noted below will be used to increase the slump.
The following preventive measures shall be taken to avoid the adverse effects of hot weather
(a) Adding water-reducing and retarding admixture to concrete.
(b) Using chilled water for mixing.
(c) Painting storage facilities, batching plants, pipes, and agitating trucks white or silver
and/or insulating the same.
(d) Keeping the transportation time to a minimum.
(e) Checking mixer drums and blades frequently during hot weather, and ensuring that the
interior of the mixer is free of any accumulated matter that will interfere with the mixing
action.
(f) Providing sufficient equipment and workers to ensure quick placing and finishing, and
so as to avoid cold jointing and plastic shrinkage cracking. All plans for the arrangement
of the equipment and workers shall be submitted to OWNER/CONTRACTOR for
approval.
(g) Using a white pigmented material when a curing compound is applied.
(h) Shading materials and facilities from the direct rays of the sun.
When the measures given above are considered insufficient to avoid the adverse effects of
hot weather, the following additional measures may be taken:
(a) Carrying out concrete placing in the evening, at night, or in the early morning.
(b) Spraying water onto the aggregate and considering new w/c ratio on design mix.
(Any water in the aggregate must be accounted for in the water-cement ratio.)
(c) Providing wind breaks during concrete placing.
(d) Using flaked ice as a part of the mixing water.
8.
MASS CONCRETE
When the concrete is considered as massive concrete in accordance with ACI 207.1R, the
requirements of ACI 207.1R should be referred to.
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9.
PRECASTING FOR CATCH BASINS, MANHOLES, PITS, AND OTHER FOUNDATIONS

The catch basin, manholes, foundations, etc. may also be precast concrete. The
SUBCONTRACTOR shall submit the items to be precast, showing the causes and merits of
such construction methods, with the procedure of the work for the approval of
CONTRACTOR.
(1) Attention shall be paid to the location, elevation and plane alignment in setting.
(2) SUBCONTRACTOR shall submit their method statement of setting work for
CONTRACTORs prior approval.
(3) When groundwater appears during excavation, replacement or improvement of subsoil
under the structures is required, and dewatering shall be carried out.
10.
INSPECTION AND TEST
10.1
Construction Tolerance
10.1.1
General
Tolerance shall conform to ACI 117, ACI 315 and ACI 347 in the case neither specified in
this section, nor in the design drawings.
10.1.2
Concrete
Table-1: Tolerance for Concrete Construction
Items to be measured
Tolerance
Variation from the plumb:
6mm in any 3m.
(In the lines and surface of columns, piers

and walls.)
25mm for entire length.
Variation of the finishing level of Elevated

Slab.
Variation of the finishing level of Surfaces to

be grouted.
6mm.
Variation of the finishing level of Floors.
6mm in any 3m.

10mm in any bay or in any 6m of length.
Variation in the thickness of slabs and walls

and in the cross-sectional dimensions of
beams and columns.
- 6mm
Misplacement of eccentricity of Footing.
2% of width in the direction of

misplacement but not more then 50mm.
Decrease of specified thickness of Footing.
Less than 5% of specified thickness.
+12mm
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10.1.3
Reinforcement
Table-2: Tolerance of Clear Distance from form surfaces (as defined in ACI 117 Sec.2.2.1)
Member Depth or Thickness
Tolerance of Reinforcement Locations
101mm or less
6 mm
over 101mm and not over 305mm
10 mm
over 305mm and not over 610mm
13 mm
over 610mm
25 mm
Table-3: Concrete Cover measured perpendicular to concrete surface (ACI 117 Sec.2.2.2)
Member Depth or Thickness
Tolerance of Concrete Cover
305mm or less
- 10mm
Over 305mm
- 13mm
Tolerance of distance between reinforcements shall be 1/4 of the specified but not larger
than 25mm.
The minimum clear spacing between parallel bars in the same layer shall be the farthest
among,
2 times of nominal diameter of rebar
4/3 times of nominal maximum size of coarse aggregate
25mm
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Anchor Bolts & Embedded Items

Table-4: Tolerance of Anchor Bolt Locations
Item to be measured.
Bolt Projection
Tolerance
+ 7mm
- 0mm
Bolt Location (without sleeves)
3mm
Bolt Location (with sleeves)
5mm
Table-5: Tolerance of Anchor Bolt Groups

Item to be measured.
Tolerance
Steel Structure (Shelters, Buildings, Piperacks

and the like)
Deviation of Group Anchor Bolts from the
Alignment shown on the drawings.
Columns/Posts in 5m
Columns/Posts in more than 5m
5mm
10mm
Equipment and Vessels

Misplacement of Anchor Bolts centroid from
the position shown on the drawings.
Table-6: Tolerance for Embedded Items
Item to be measured
Inclination from true in any direction
5mm
Tolerance
1/200
Offset
5mm
Elevation
5mm
10.2
Inspection and Test
10.2.1
General
Inspection and test shall confirm to ACI 311 if not specified in this section.
Also please refer to related QC inspection and test plan for concrete work.
10.2.2
Sampling for Test

The sampling and slump test of freshly mixed concrete shall be performed at the point of
delivery.
10.2.3
Slump Test
The slump tests shall be carried out in accordance with the following:
All slump test shall be carried out in accordance with the requirement of ASTM C143.
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Slump test shall be performed at each delivery of concrete.

The result of the tests shall show that the slump is within the range specified in the
construction drawing, or the concrete shall not be placed.
The temperature of fresh concrete shall also be checked at the time of slump test.
10.2.4
Compressive Strength Test

Compressive strength tests shall be carried out for each class of concrete, in accordance
with the following procedures:
(1) Samples of concrete for compressive strength test specimens shall be obtained in
accordance with the requirements of ASTM C172.
(2) A minimum of 4 specimens shall be molded and cured in accordance with the
requirements of ASTM C31.
(3) Compressive strength tests of cylinders shall be carried out in accordance with the
requirements of ASTM C39. These cylinders shall be tested as follows:
one at 7 days for information

Three at 28 days for determining acceptability of concrete strength
Evaluation and acceptance of concrete shall be in accordance with ACI 318.
Samples shall be taken from each complete pour for individual foundations or structures
supporting main processing units, heavy mechanical equipment, buildings, storage tanks,
and from other important concrete structures. At least two samples shall be taken from each
full days concreting or not less than required by the following.
Cubic Meters in Any
Individual Foundation or Structure
10.2.5
Samples to be Taken
(4 Cylinders per Sample)
0-38
One sample for each 20 cubic meters
39 -150
151 - 270
Greater than 270
Water Filling Test for Concrete Ponds/Pits

For concrete ponds/pits that are designed to retain contaminated water such as oil and
chemicals, a water-filling test shall be carried out before back filling of the pond. Water-filling
test is not required for seawater or clean water ponds unless the high water level is higher
than ground elevation. Water shall be filled to the design high water level, a minimum of 24
hours is required before inspection. Concrete ponds shall be back filled only after approval of
OWNER/CONTRACTOR.
The acceptance criterion for water filling test is that no water leak is observed on the external
surface of the concrete pit. If the leakage is found, the defected parts shall be repaired
according to the section 6 above, then inspect the parts again until no leakage is observed.
The use of sea water and storm water is not permitted for the test.
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Test Reports
All test reports shall be submitted to OWNER/CONTRACTOR upon completion of tests.

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DOC. No.

Donggi Senoro LNG Project

For Construction (revised as marked)

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

CONSTRUCTION SPECIFICATION ...................................................................................................... 1

INGREDIENTS OF CONCRETE ..................................................................................................... 5

CONCRETE MIXING ....................................................................................................................... 8

REPAIR OF SURFACE DEFECTS ...............................................................................................17

HOT WEATHER CONCRETE.......................................................................................................18

PRECASTING FOR CATCH BASINS, MANHOLES, PITS, AND OTHER FOUNDATIONS......19

INSPECTION AND TEST ..........................................................................................................19

10.1 Construction Tolerance...........................................................................................................19

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

Codes and Standards

Standard Specifications for Tolerances for Concrete Construction and

Standard Practice for Selecting Proportions for Normal, Heavyweight, and

Specification for Structural Concrete

Guide for Concrete Floor and Slab Construction

Guide for Measuring, Mixing, Transporting, and Placing Concrete

Placing Concrete by Pumping Methods

Hot Weather Concreting

Standard Practice for Curing Concrete

Building Code Requirements for Structural Concrete

Guide to Formwork for Concrete

Code Requirements for Environmental Engineering Concrete Structures

Guide to Joint Sealants for Concrete Structures

ACI Manual of Concrete Inspection

ACI Design Handbook

ACI Detailing Manual

Foundation for Equipment and Machinery

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

American Standards for Test and Materials

Standard Specification for Steel Welded Wire Fabric, Plain, for

Standard Specification for Deformed and Plain Billet-Steel Bars for

Project Specifications and Drawings

Application for Grouting of Rotating Equipment

D-900-1310-001 Standard Drawing for Civil General Notes

Rejection of Cement Material

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

Beams, Columns, Walls

Exposed to sea water

Production by Batch Plant

Batching and mixing units

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

hereunder for OWNER/CONTRACTORs approval before commencing related works.

Measuring and Batching

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

(5) Control of Admixtures

Production by In-Situ Concrete Mixer

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

Foundations walls, footings, slabs, etc

Fabrication and Placing of Rebars

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

Design and Installation of Formwork

CONSTRUCTION SPECIFICATION FOR CONCRETE WORK

Preparation of Form Surface

:12 hours (Note 1)

Columns and Pedestals

:12 hours (Note 1)

Sides of Beams, Girders and Footings

:12 hours (Note 1)

Joist, Beam or Girder Soffits: