DGS-CU-015-R2 on-site Concrete Batch Plant and Delivery (2)

Abu Dhabi Oil Refining Company

ON-SITE CONCRETE BATCH PLANT AND DELIVERY DGS-CU-015 Rev-2 Mar 2009

Takreer DGS-CU-015 Rev-2 Mar-2009 Printed 25-Mar-09 11:23:38 Initials Page 1 of 9

ON-SITE CONCRETE BATCH PLANT AND DELIVERY

Amendment History

02 Mar-09 AMD-CU-015-002-BECHTEL Clause 2, 16 FK/DDC QAM Mar-09

01 Dec-07 AMD-CU-015-001-ETSD Clause 1,2,4,8,10,12 AB/DDC QAM Jan-08

No Date Amendment Description Proposed Approved Incorporated

DGS History

2 Mar 2009 DGS-CU-015-Rev-2 AMD-CU-015-002-BECHTEL FK/DDC QAM/MAY

1 Jan 2008 DGS-CU-015-Rev-1 AMD-CU-015-001-ETSD AB/DDC QAM/MAY

0 Mar 2006 DGS-CU-015-Rev-0 Previous Project / Lessons Learnt Incorporated

AB/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-CU-015-Rev-2




TABLE OF CONTENTS

1.0 GENERAL .............................................................................................................................. 3 2.0 CODES AND STANDARDS.................................................................................................... 3 3.0 REFERENCE DOCUMENTS ................................................................................................. 4 4.0 DOCUMENT PRECEDENCE................................................................................................. 4 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL..................................................... 4 6.0 QUALITY ASSURANCE/QUALITY CONTROL ...................................................................... 5 7.0 DOCUMENTATION ................................................................................................................ 5 8.0 BATCH PLANT ....................................................................................................................... 5 9.0 MATERIALS ........................................................................................................................... 7 10.0 MATERIAL STORAGE AND HANDLING................................................................................ 7 11.0 CONCRETE DELIVERY......................................................................................................... 8 12.0 FACILITIES INSPECTION AND CALIBRATION..................................................................... 8 13.0 RECORDS ............................................................................................................................. 8 14.0 REPORTS .............................................................................................................................. 9 15.0 LIAISON WITH ON-SITE TESTING LABORATORY .............................................................. 9

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD: -------------------

DGS Discipline Committee Member, RRD: -------------------

DGS Discipline Committee Member Leader, E&PD: -------------------

Engineering & Technical Services Manager, E&PD: -------------------

Engineering & Projects Division Manager, E&PD: -------------------




1.0 GENERAL 1.1 SCOPE

This specification defines the minimum requirements for production and delivery of ready-mixed concrete.

1.2 PURPOSE This specification is intended for commercially producing ready-mixed concrete batch plants or for establishing an independent on-site batch plant for production and delivery of ready-mixed concrete including:

Facilities for receiving, storing, handling, cleaning and proportioning materials required to produce concrete.

Delivering concrete in appropriate transporting system to various areas of jobsite. 1.3 DEFINITIONS

For the purposes of this specification the following definitions shall apply:

CONCESSION REQUEST A deviation requested by the CONTRACTOR, SUBCONTRACTOR or VENDOR usually after receiving the contract package of purchase order. Often it refers to an authorization to use, repair, recondition, reclaim or release materials already in progress or completely furnished or installed, but does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

CONTRACTOR The party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of the Project.

MANUFACTURER/VENDOR The party that manufactures and/or supplies material, equipment, technical documents/drawings and services to perform the duties specified by CONTRACTOR.

SHALL Indicates a mandatory requirement. SHOULD - Use of the word should indicates a strong recommendation to comply with the requirements of this document.

SUBCONTRACTOR The party(ies) that carries(y) out all or part of the design, procurement, installation and testing of the system(s) specified by the CONTRACTOR.

2.0 CODES AND STANDARDS The following codes and standards to the extent specified herein form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force shall apply.

American Concrete Institute (ACI):

ACI 304R Guide for Measuring, Mixing, Transportation and Placing Concrete

American Society for Testing and Materials (ASTM):

ASTM C94 / C94M Standard Specification for Ready Mixed Concrete




National Ready Mixed Concrete Association (NRMCA):

NRMCA QC 3 Quality Control Manual: Section 3, Plant Certifications Checklist: Certification of Ready- Mixed Concrete Production Facilities

ISO (International Organization for Standardization):

ISO 9001-2000 Quality Management System - Requirements

ISO 9004-2000 Quality Management Systems - Guidelines for Performance Improvements

IS0 19011 Guidelines for Quality and/or Environmental System Auditing

3.0 REFERENCE DOCUMENTS

Project Specifications:

DGS-CU-014 Concrete Mix Design

DGS-CU-016 Testing Laboratory

DGS-MU-002 Preservation and Export Packing

4.0 DOCUMENT PRECEDENCE It shall be the SUBCONTRACTORS responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The SUBCONTRACTOR shall notify the CONTRACTOR of any apparent conflict between this specification, the codes and Standards and any other Project Specification noted herein. Resolution and/or interpretation of precedence shall be obtained from the CONTRACTOR in writing before proceeding with the work.

In case of conflict, the order of precedence shall be as stated in the AGREEMENT or other PROJECT documents as applicable. In the absence of such provisions the following order of precedence shall prevail:

Contract Drawings Scope of Work, Engineering Narratives and Design Philosophies Project Specifications Standard Drawings Industry Codes and Standards

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Project Specifications shall be sought only through CONCESSION REQUEST format. CONCESSION REQUESTS require the CONTRACTOR'S and COMPANYs review/approval prior to the proposed technical changes being implemented. Technical changes implemented prior to approval are subject to rejection.




Any substitution of material as an approved equal must have prior written approval by the contractor and COMPANY through CONCESSION REQUEST format. The SUBCONTRACTOR shall include catalog samples (if applicable) and the test data required for proper engineering evaluation.

6.0 QUALITY ASSURANCE/QUALITY CONTROL The SUBCONTRACTOR shall have in effect at all times, a QA/QC program which clearly establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identity, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.

SUBCONTRACTORS proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality systems shall provide for the planned and systematic control of all quality-related activities performed during execution of the work. Implementation of the system shall be in accordance with the SUBCONTRACTOR'S Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures be submitted to the CONTRACTOR for review, comment and approval.

The CONTRACTOR reserves the right to inspect materials and workmanship at all stages of concrete production and delivery and to witness any or all tests. The SUBCONTRACTOR, 30 days after award, but prior to the pre-inspection meeting, shall provide the CONTRACTOR with a copy of the Inspection plan for review and inclusion of any mandatory CONTRACTOR witness points.

7.0 DOCUMENTATION The Batch Plant SUBCONTRACTOR shall submit the following in accordance with the Vendor Drawing and Data requirements section of the Purchase Order/ Subcontract:

Overall plant layout, batch plant system description, equipment and operational details including automation, computerization, concrete transportation mixer truck operation and operator qualifications

All records and reports as described in Sections 13.0 and 14.0 respectively Batch tickets

8.0 BATCH PLANT The batch plant, including storage facilities, and delivery trucks shall meet the requirements of ASTM C94 / C94M and ACI 304R Chapters 2, 3, and 4. The batch plant, including storage facilities, and delivery trucks shall be capable of producing the concrete grades specified in DGS-CU-014, Concrete Mix Design, and shall be able to become certified in accordance with the certification process of NRMCA QC 3. The subcontractor shall be fully responsible for the specified quality of the concrete, up to the discharge end of the delivery equipment chute.

The batch plant shall include, but not be limited to:

Full automation Full computerization




Full segregation of materials Shaded and covered areas for materials to prevent contamination by rain, dirt, sand,

mud, air borne chlorides, dust and other contaminants

Facilities for washing and cleaning materials with adequate drainage Automatic compensation for moisture in fine aggregate Adequate ice and chilled water plants with automatic feeding lines Adequate production capacity Back up facilities (which may be as great as 100% for certain situations) Ability to provide computer print out of mix design together with actual mix Ability to provide computer calculation and print out of actual water/cement ratio The subcontractor shall ensure that the concrete is mixed in a fully automatic computerized batching plant.

The mixing pan capacity shall be selected to ensure that the required maximum production can be comfortably achieved.

The weights of fine and coarse aggregates shall be automatically adjusted to allow for any free water or excess moisture contained in them. Accordingly, the amount of water to be added shall be reduced by the amount of free water or excess moisture contained in the aggregates.

The quantities of all materials for concrete shall be charged to the pan by weight (water by volume).

Admixtures that have been approved as part of the mix design shall be added by approved automatic dosing equipment capable of feeding fixed quantities into the mixing water before the water is charged into the mixer.

The measuring equipment shall be maintained in a clean, serviceable condition.

Mixing shall continue until uniform distribution of materials and uniformity of consistency and color is obtained.

The subcontractor shall ensure that the materials used for each batch in the mixer do not exceed the manufacturer's rated capacity for the machine. The machine shall be kept clean, free of any residual material after depositing each batch of concrete and the mixer pan drum shall be washed and cleaned out immediately following the completion of each concreting operation.

The batch plant shall be able to provide a computer printout batch ticket of the following for each truck:

Serial number of ticket Date Truck number Grade of concrete Amount of concrete




Amount of cement and slag Information necessary to calculate total mixing water added (free water on

aggregates, water, and ice batched at plant)

Type, brand, and amount of admixtures Weights of fine and coarse aggregate Time loaded or time of first mixing of cement and aggregates Reading of revolution counter at the first addition of water Time and reading of revolution counter at the time of the start of discharge of the

load of concrete

Unique location identification as provided by the structure number and concrete placement number

Signature or initials of batch plant representative 9.0 MATERIALS

All materials required for the production of ready-mixed concrete shall in accordance with Project Specification DGS-CU-014, Concrete Mix Design.

All materials must be selected from the approved sources identified in Project Specification DGS-CU-014, Concrete Mix Design. The subcontractor shall record on a daily basis the quantity of materials received.

Records shall be maintained to indicate:

MANUFACTURER'S details pertaining to cement and admixtures, and test data of aggregates and sands

Fully detailed data sheets showing all chemical and physical information Recent test results (not older than three months) Details of MANUFACTURER'S Quality Assurance System Details of MANUFACTURER'S Quality Control procedures

10.0 MATERIAL STORAGE AND HANDLING 10.1 CEMENT STORAGE

Cement storage arrangement shall allow easy access for inspection and identification of each shipment in accordance with test reports. Each shipment shall be used in the order in which it is delivered to the site.

Bagged cement shall be transported to the batch plant in the MANUFACTURER'S original sealed bags or containers and shall be stored in a dry, weather-tight, properly ventilated covered structure, with adequate provisions for preventing the absorption of moisture, and raised at least 150 mm off the floor to prevent deterioration. The storage block shall be large enough to allow sufficient cement to be kept to allow continuity of work. Not more than 10 small bags or 3 Big Bags shall be piled one on top of the other while stored at site. Suitable shading shall be provided to limit the temperature to 40 C.




Temperature of cement stored in bulk silos shall not exceed 75 C. No cement shall be stored on site for more than three months.

10.2 STORAGE OF AGGREGATES The concrete plant shall at all times maintain sufficient quantities of each type of aggregate to ensure continuity of work.

Each type and grade of aggregate shall be stored separately in bins in such a manner that segregation of the various size particles shall not occur. The floors of the bins shall be of concrete or other approved material having sufficient slope to ensure adequate drainage of aggregates before being used for concreting.

Strict precautions shall be taken to avoid contamination of aggregates by wind blown dust, chlorides, etc.

Suitable shading shall be provided to control the temperature and any contamination, especially from chlorides.

Storage bins shall be emptied and cleaned at regular intervals.

11.0 CONCRETE DELIVERY Delivery Trucks shall be of revolving drum type, watertight, and so constructed that the concrete can be conveyed and discharged into the pumps at site maintaining the uniform distribution of materials throughout the mass. The drum shall be painted white and kept clean to ensure maximum reflectivity.

The maximum size of batch in truck mixers shall not exceed the maximum rated capacity of the mixer as stated by the MANUFACTURER and stamped in metal on the mixer.

On no account shall water from the concrete truck be used in the mix. Concrete trucks shall have their water tanks completely disconnected from the drum.

Concrete temperature when discharged in the formwork shall not be more than 30 C. For thick elements the temperature shall be less than 24 C. Thick elements shall be defined as any concrete member that has both plan and cross sectional dimensions exceeding one meter, and containing a total volume exceeding six cubic meters.

12.0 FACILITIES INSPECTION AND CALIBRATION At intervals not exceeding 90 days, all scales, volumetric devices, and dispensers of the batch plant shall be inspected and calibrated. The accuracy of the measuring equipment shall be within 3%.

At intervals not exceeding 90 days revolution counters shall be inspected and calibrated prior to use for hauling or mixing concrete.

At intervals not exceeding 90 days, the batch plant mixers and mixer trucks shall be visually examined to detect changes in condition due to accumulation of hardened concrete and examined to detect wear of blades. Mixer blades shall be replaced when they have lost 10% of their original height in accordance with NRMCA QC3. Restrictions shall conform to requirements of ASTM C94 / C94M.

13.0 RECORDS Records shall be maintained for the following:




Material certification reports received with all delivered materials (cement, slag, aggregate, and admixtures), as described in Section 9.0. Originals of these documents shall be sent to the testing laboratory for retention. Copies of these documents shall be retained at the batch plant.

Required testing of materials at the batch plant as set forth in Project Specification, DGS-CU-016, Testing Laboratory. Copies of these test reports shall be retained at the batch plant, originals of these test reports shall be retained by the testing laboratory.

Records of maintenance of all batch plant and delivery equipment based on MANUFACTURER'S recommendations on a 90 day basis.

Records of all required inspections and calibrations, as described in Section 12.0. 14.0 REPORTS

The subcontractor shall provide a detailed weekly summary report to the CONTRACTOR pertaining, but not limited to, the following:

All aspects of material acquisition, transporting, storage, handling, batching, production of concrete and transportation of the concrete to the jobsite.

The operating aspects of plant equipment, computerization and any problems encountered during the production of concrete.

The liaison aspects of subcontractors work with the mix design specialist and the testing laboratory.

Deviations in concrete mix production from the approved mix design and documentation.

15.0 LIAISON WITH ON-SITE TESTING LABORATORY All material tests will be performed by an on-site testing laboratory. The subcontractor shall facilitate the work of, and cooperate with the laboratory inspectors at all time.

16.0 SUBCONTRACTORS / VENDORS

The CONTRACTOR has full responsibility for the On-Site Concrete Batch Plant.

It is the CONTRACTOR;s responsibility to enforce all contract and project specification requirements on its Subcontractors and Vendors.

The CONTRACTOR shall obtain COMPANY approval for all of its Subcontractors and Vendors.

DGS-CU-015-R2 on-site Concrete Batch Plant and Delivery (2)

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Transcript of DGS-CU-015-R2 on-site Concrete Batch Plant and Delivery (2)