GP 04-01-01 Concrete Design and Construction November 2005

Concrete Design and Construction

GP 04-01-01

Scope
1) [I] This Global Practice (GP) covers the design and construction of concrete structures.
2) [I] An asterisk (*) indicates that additional information from Owner is required or approval by Owner
is required.

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 GP 04-01-01 Concrete Design and Construction November 2005

Table of Contents

Table of Tables .............................................................................................................. 3

1. Required References ............................................................................................ 4

1.1. ACI–American Concrete Institute ................................................................. 4
1.2. ASTM–American Society for Testing and Materials ..................................... 4
2. Additional References .......................................................................................... 4
2.1. Global Practices–ExxonMobil Engineering Practices ................................... 5
2.2. ACI–American Concrete Institute ................................................................. 5
2.3. ASTM–American Society for Testing and Materials ..................................... 5
3. Materials................................................................................................................. 5

4. Construction .......................................................................................................... 8
4.1. Placement .................................................................................................... 8
4.2. Joints ............................................................................................................ 8
4.3. Finishing ....................................................................................................... 8
5. Concrete Design.................................................................................................... 9

6. Inspection and Testing ....................................................................................... 10

7. Additional Requirements for Marine Structures ............................................... 10

8. Additional Requirements for Liquid Retaining Structures .............................. 11

Record of Change ....................................................................................................... 12

Attachment: Purpose Codes Definitions.................................................................. 13

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Table of Tables

Table 1: Application and Compressive Strength of Concrete .................................. 7

Table 2: Finishes for Horizontal Surfaces .................................................................. 8

Table 3: Minimum Time for Form Removal ................................................................ 9

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1. Required References
1) This Section lists Practices and Standards that are referenced and assumed to be a part of this
document. Unless otherwise specified herein, use the latest edition.
2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the
following provisions are met:
a) The resultant design meets the safety and serviceability criteria attained through this GP.
b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's
Engineer.

1.1. ACI–American Concrete Institute

ACI 117/117R Standard Specification for Tolerances for Concrete Construction and
Materials
ACI 301 Specifications for Structural Concrete
ACI 308R Guide to Curing Concrete
ACI 318/318R Building Code Requirements for Structural Concrete and Commentary

1.2. ASTM–American Society for Testing and Materials

ASTM A 615/A 615M Standard Specification for Deformed and Plain Carbon Steel Bars for
Concrete Reinforcement
ASTM C 31/C 31M Standard Practice for Making and Curing Concrete Test Specimens in
the Field
ASTM C 94/C 94M Standard Specification for Ready-Mixed Concrete
ASTM C 150 Standard Specification for Portland Cement
ASTM C 192/C 192M Standard Practice for Making and Curing Concrete Test Specimens in
the Laboratory

2. Additional References
1) The following Practices and Standards shall be used with this GP as applicable.
2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the
following provisions are met:
a) The resultant design meets the safety and serviceability criteria attained through this GP.
b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's
Engineer.
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 GP 04-01-01 Concrete Design and Construction November 2005

2.1. Global Practices–ExxonMobil Engineering Practices

GP 07-01-01 Fired Heaters
GP 16-03-01 Wiring Methods and Material Selection

2.2. ACI–American Concrete Institute

ACI 207.1R Mass Concrete
ACI 207.2R Effect of Restraint, Volume Change, and Reinforcement on Cracking of
Mass Concrete
ACI 305R Hot Weather Concreting
ACI 306R Cold Weather Concreting
ACI 350/350R Code Requirements for Environmental Engineering Concrete Structures
and Commentary
ACI 357R Guide for the Design and Construction of Fixed Offshore Concrete
Structures

2.3. ASTM–American Society for Testing and Materials

ASTM A 767/A 767M Standard Specification for Zinc-Coated (Galvanized) Steel Bars for
Concrete Reinforcement
ASTM A 775/A 775M Standard Specification for Epoxy-Coated Steel Reinforcing Bars

3. Materials
1) [I] Concrete shall be per ACI 318/318R.
2) [R] All reinforcing bars shall be ASTM A 615/A 615M Grade 60 unless otherwise specified.
3) * [I] Contractor shall submit a statement detailing the concrete mix design for approval by the
Owner's Engineer. This statement shall include properties of the materials, proportions of cement,
water and aggregates by weight and type, and quantity of admixtures (if any) proposed for each class
of concrete required.
4) [R] Concrete mix design shall consider environmental exposure and potential chemical attack and
shall specify the use of beneficial admixtures such as air entrainment, fly ash, and other pozzolanic
materials.
5) [R] Maximum water cementitious ratio shall be minimized to maximize durability but shall in no case
be more than 0.50. The maximum water cementitious ratio shall be 0.40 where the concrete will be
exposed to either a chloride or marine environment and 0.45 when exposed to freezing/thawing
conditions, deicing chemicals, or a sulfate environment.

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6) Concrete mix design should consider the potential for alkali silica reaction in the concrete and
whether field tests are required.
7) [R] Design strength of concrete mixes shall be in accordance with ACI 318/318R for service exposure
and not less than those given in Table 1 and the following:
a) In countries where testing is done on cubes, cylinders shall also be made and tested in order to
establish a correlation between the required strengths for the cylinder and the cube specimens.
b) Lacking adequate laboratory facilities for testing such cylinders, the 28-day compressive
strengths of 4 in., 6 in., and 8 in. cubes (100, 150, and 200 mm) must be at least 130 percent, 125
percent, and 120 percent respectively, of specified cylinder strengths.
8) * [R] Cement shall be per ASTM C 150 and selection of cement type shall be governed by the
following:
a) For concrete exposed to soils or other materials having low pH values (less than 5.0 if continuous
replenishment of acidity), special cement type or other measures may be required as directed by
the Owner's Engineer.
b) Selection of cement type for concrete for structures exposed to seawater environment shall be per
ACI 318/318R for "moderate exposure," except that the maximum water-cement ratio shall be
0.40.
9) * [R] Admixtures shall be approved by the Owner's Engineer. Calcium chloride admixtures shall not
be used.

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Table 1: Application and Compressive Strength of Concrete

Minimum
Compressive
Group Application
Strength (2)
psi (MPa)
A Concrete for structures located in a marine environment 5000 (34.5)
B Prestressed or precast concrete structures 4000 (27.6)
Precast piling
Liquid retaining structures
Concrete for fireproofing
C Precast pipe 3500 (24.1)
Precast concrete sills, copings, and all ornamental concrete
Reinforced concrete chimneys
Foundations for tanks in sulfuric acid service
D Girders, beams, walls, slabs, piers, and columns 3000 (20.7)
Superstructure for docks and bridges
Pipe supports
Concrete on or below grade, such as footings, cast-in-place
piles, pile caps, tie beams, grade beams, anchor blocks,
pump blocks, catch basins, manholes, sidewalks and
paving(1)
Concrete for structures not listed
E Concrete for underground electrical (protective cover, etc.) 2000 (13.8)
F Low strength concrete for filling purposes where mass, 1500 (10.3)
rather than strength, is the principal requirement
Notes:
(1) For concrete exposed to moderate sulfate attack (per ACI 318/318R) and where
cement with less than 8 percent C3A is not available, cement with up to 12 percent
C3A may be used if approved by Owner's Engineer, and provided that concrete
strength is increased to at least 3500 psi.
(2) The values above represent the 28-day compressive strength of normal Portland
cement concrete (or 7-day compressive strength of high-early strength concrete) as
determined by tests on 6 in. diameter by 12 in. high (150 mm x 300 mm) cylinders per
ASTM C 31/C 31M or ASTM C 192/C 192M.

10) [R] All reinforcement shall be bent-cold.

11) [R], [M] All concrete used for underground electrical work shall be per GP 16-03-01.
12) [R] All concrete used for underground air ducts for fired heaters shall be per GP 07-01-01.

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4. Construction
[I], [R] Concrete construction shall be per ACI 301 and ACI 318/318R and the following:

4.1. Placement
1) * [R] Concrete shall not be placed prior to approval from the Owner's Engineer.
2) [R] Concrete placement shall be in accordance with the recommendations per ACI 306R when the
ambient temperature drops below 40°F (4°C).
3) [R] Concrete placement shall be in accordance with the recommendations per ACI 305R when the
ambient temperature exceeds 90°F (32°C).
4) [R] Field alterations of the concrete mix proportions are prohibited unless approved by Manufacturer
and Owner's Engineer.
5) [R] Concrete poured against earth shall have the soil prewetted or sealed with a vapor barrier to
prevent excessive loss of moisture from the fresh concrete.

4.2. Joints
* [I] Construction, contraction, and expansion joints shall be located as specified. Any additional joints
shall be approved by the Owner's Engineer. Expansion joints shall be constructed with approved
preformed filler material and adequately sealed with an approved sealant.

4.3. Finishing
1) [R], [M] Surface finishes for horizontal surfaces shall be as specified in Table 2 unless otherwise
specified.

Table 2: Finishes for Horizontal Surfaces

Surface Finish
Area Paving Broom or Belt
Compressor House Floors Broom or Belt
Cooling Tower Basin, Flume Floated
Curbs Broom or Belt
Foundations and Pedestals to be Grouted Scratched
Platforms, Stair Pads, Concrete Stairs Broom or Belt
Pumps Slabs Broom or Belt
Seal Slabs None
Surfaces to be Covered with Resilient Flooring (Asphalt Tile, Etc.) Troweled
Stucco or Mortar Base Scratched

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Surface Finish

Suction Pits Floated

Terrazzo Base Scratched

2) [R] Unless otherwise specified, the vertical surfaces of walls, foundations, and other formed
structures shall be finished as follows:
a) Surfaces shall remain as they are when the forms are removed, except holes left by withdrawal of
form ties shall be filled solid with grout and finished to match the surrounding surface.
b) Rubbing of surfaces is not required.
3) [R] All exposed corners and edges of concrete shall have 3/ 4 in. chamfer unless otherwise specified on
the design drawings.
4) [R] Concrete curing shall be per ACI 308R. Minimum time for form removal after concrete
placement shall be per Table 3 provided that the forms are not necessary for the structural support of
the concrete.

Table 3: Minimum Time for Form Removal

Minimum Time (hours)

Type of Construction Standard Standard

(ASTM C150, Type I) (ASTM C150, Type III)
Cement Concrete Cement Concrete
Tank Rings, Pump Foundations and 24 18
Similar Low Structures
Walls, Columns, and Similar Tall 48 24
Structures
Horizontal Beams or similar
components which require bottom
support:
Bottom 168 72

Side Forms 24 18

5. Concrete Design
1) [I] Concrete design shall be per ACI 318/318R.
2) * [O], [R] For inground structures the safety factor against flotation shall be not less than 1.2 for both
normal operation and erection. Buoyant forces shall be calculated with the ground water level

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assumed to be at the finished grade elevation. Pressure relief systems, deliberate flooding, or other
extraordinary methods to prevent flotation shall only be used if approved by the Owner's Engineer.
3) * [I] The extent of paving and toes walls within process unit areas to control spillage, and for drainage
of storm, process and firewater shall be specified.
4) * [R] Pump slab areas handling corrosive chemicals shall have the paved areas around the pumps and
other equipment and toe walls coated as specified.
5) * [I] Concrete duct designs for air temperatures greater than 200°F (93°C) shall be approved by the
Owner's Engineer.
6) [I] Embedded items, such as inserts, hangers, pipe supports and sleeves, conduits and drains, shall be
adequately secured before concrete is placed.
7) [R] When the least dimension of a concrete element is greater than 4 ft (1.2 m), concrete construction
and temperature control shall be per ACI 207.1R and ACI 207.2R to prevent thermally induced
cracking during hydration.

6. Inspection and Testing

1) * [R] Concrete requiring a compressive strength of 3,000 psi (20.7 MPa) or more shall be tested in
accordance with ACI 318/318R, except as follows:
a) One test shall be taken for each day's pour and at least one test be taken for each 50 cubic yards
(38 m3) placed. In addition, at least one test shall be made for each foundation exceeding 20
cubic yards (15 m3).
b) A test shall consist of four cylinders. One such cylinder shall be tested in the laboratory after
seven days and two after 28 days with results submitted to the Owner's Engineer as soon as
possible. Testing of the remaining cylinder shall be performed as directed by the Owner's
Engineer.
2) * [O], [R] Concrete showing structural defects shall be repaired or replaced by a method which has
been approved by the Owner's Engineer. Concrete showing surface defects shall be patched.
3) [R] Air content, slump, and temperature tests shall be taken from the concrete samples for each
strength test and whenever the consistency of the concrete appears to vary.

7. Additional Requirements for Marine Structures

1) [I] The three zones of exposure to be considered on a marine structure are:
a) The submerged zone, which can be assumed to be continuously covered by water.
b) The splash zone, the area subject to continuous wetting and drying.
c) The atmospheric zone, the portion of the structure above the splash zone.
2) [R] Minimum cover over reinforcing steel shall be 2.5 in. (65 mm).
3) * [R] Where specified, reinforcing steel shall be galvanized per ASTM A 767/A 767M or epoxy
coated per ASTM A 775/A 775M to increase their corrosion resistance.
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4) Selection of cement type for concrete for structures exposed to seawater environment shall be
designed and constructed per ACI 357R.

8. Additional Requirements for Liquid Retaining Structures

1) [I] Liquid retaining structures shall include inground concrete pits sensitive to groundwater intrusion
and aboveground or inground concrete structures required to contain liquids.
2) [R] Liquid retaining structures shall be designed and constructed for liquid tightness according to the
provisions of ACI 350/350R, except structural design considerations shall be as clarified in Section 8,
Item 3, below.
3) * [R] To minimize cracking and leakage, design of concrete walls, slabs and other elements which
serve to retain liquids shall be in accordance with the following criteria:
a) Minimum thickness and changes in thickness shall be as follows:
i) Walls up to 10 ft (3 m) high shall have a minimum thickness of (4+0.8 H) in. [(100+67 H)
mm] but not less than 8 in. (200 mm) where H equals the wall height in feet (meters). The
minimum thickness for walls above 10 ft (3 m) in height shall be 12 in. (305 mm).
ii) Slabs shall have a minimum thickness of 10 in. (250 mm).
iii) Changes in wall or slab thickness shall be accomplished using tapered sections having a
minimum length of three times the change in thickness.
b) Reinforcing bar diameters shall not exceed 6 percent of the thickness of the wall or slab.
c) Expansion joints shall be spaced not more than 50 ft (15 m) apart for exposed members and not
more than 80 ft (24 m) apart for members completely underground.
d) Construction joints not shown on the drawings shall be approved by the Owner's Engineer.
4) * [R] Construction of liquid retaining structures shall conform to ACI 301 and the following:
a) The surface of concrete at all joints shall be thoroughly cleaned and all laitance removed before
placing adjoining concrete.
b) Special liners and coatings shall be used to protect concrete surfaces from degradation by harmful
liquids. Materials used for liners and coatings shall be approved by the Owner's Engineer.
5) * [R] Structures required to contain liquid shall pass a water-tightness test approved by the Owner's
Engineer.

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Record of Change
Version 1.0.0 Date: 02/02
Location Action Description
Initial Publish.

Version 1.1.0 Date: 03/02

Section 5 Addition Added Purpose Code [I] to Item 6

Version 1.1.0 Date: 07/03

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 2.0.0 Date: 11/05

Section 2.2 Addition Reference to ACI 207.1R and ACI 207.2R for mass concrete design
considerations.
Section 2.2 Addition Reference to ACI 357R for concrete located in marine environments.
Section 3, Addition Requirements to ensure durability of concrete.
Items (4) – (6)
Section 3, Item Modification Selection of concrete located in marine environment shall be in
(5b) accordance with ACI 357R in lieu of ACI 318. Item moved to Section
7, Item (4). Also eliminated maximum water cement ratio of 0.40.
Section 3, Item Deletion Duplicate requirements already specified in ACI 318.
(10)
Section 3, Item Deletion Duplicate requirements already specified in ACI 318.
(11)
Table 1 – Modification Clarified that marine environment includes both brackish and freshwater
Group A environments.
Table 1 – Modification Eliminated reference to structures continuously exposed to freshwater.
Group B
Section 5, Item Addition Reference to ACI 207.1R and ACI 207.2R for design of mass concrete.
(7)
Section 7, Item Modification Minimum cover for concrete structures in marine environment.
(2)

Version 2.0.0 Date: 12/05

Upstream initial customization to Version 2.0.0.

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GP 04-01-01 Concrete Design and Construction November 2005

Attachment: Purpose Codes Definitions

Code Description
C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.
Reduced cost in this context refers to initial investment cost and does not include Life-Cycle
cost considerations. Life-Cycle cost considerations are captured under reliability,
maintainability, or operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-
stream operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure
operability of equipment or systems. Operability is the ability of the equipment/system to
perform satisfactorily even though conditions are off-design, such as during start-ups, process
swings, subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or
assure the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety
policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries—i.e., burns, cuts,
abrasions, inhalation, or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, explosions,
Safety: etc.

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