QCP-795-210_1

JGC ARABIA LTD. CONSOLIDATED CONTRACTORS COMPANY

QUALITY CONTROL PROCEDURE

PLACEMENT OF EARTH WORKS, SUB-BASE & BASE COURSE MATERIALS

QCP-795-210

SAUDI ARAMCO

COGENERATION AT BERRI GAS PLANT PROJECT

SAUDI ARABIA

1Incorporated Saudi Aramco

Comments & Issued For Implementation

08.11.03

0 For Review & Comments 19.10.03 PM AM

REV DESCRIPTION DATE Quality Mgr.

CCC

Site Constr. Mgr.

CCC

Qualtiy Mgr.

JGC

Site Project Mgr.

JGCPREPARED BY CHECKED BY REVIEWED BY APPROVED BY

C:\QAQC\BCOG document.doc of 8


Placement of Earth Works, Sub-Base & Base Course Materials.

QCP-795-210 Rev. 1

Index

1. Scope

2. Purpose

3. References

4. Definitions

5. Responsibilities

6. Procedure

7. Attachments




QCP-795-210 Rev. 1

1. SCOPE

1.1 This Procedure encompasses QC inspection activities related to earthworks excavations, evaluation of material suitability for filling and compaction operations related to foundations, trenches, road embankments, sub-bases, crushed base materials, natural ground stabilization and bund walls.

2. PURPOSE

2.1 This Procedure defines the type and extent of QC sampling and testing to be conducted in order to verify that the excavation, filling and compaction, base compaction and suitability of materials conform to specified requirements. Additional sampling and testing requirements may be defined in ITPs.

3. REFERENCES

3.1 SAES-M-100 Appendix Chapter A33 SAUDI ARAMCO Building Code section “Excavation & Grading”

3.2 SAES-Q-005 SAUDI ARAMCO Engineering Standard “Concrete Foundations”

3.3 SAES-S-070 SAUDI ARAMCO Engineering Standard “Installation of Utility Piping Systems”

3.4 Geotechnical Report No. PP-601001

3.5 SAES-Q-006 SAUDI ARAMCO Engineering Standard “Asphalt Concrete Paving”

3.6 SAES-M-100 SAUDI ARAMCO Building Code.

3.7 JGC Specification Construction Specification for Earth Works

3.8 SAES-A-114 Excavation and Backfill

3.9 PIP CVS02100 Site Preparation, Excavation & Backfill Specification

3.10 Saudi Aramco Construction Safety Manual

4. DEFINITIONS

4.1 QMP : Quality Management Procedure

4.2 QCP : Quality Control Procedure

4.3 ITP : Inspection & Test Plan


1



QCP-795-210 Rev. 1

4.4 Company : Saudi Aramco.

4.5 Contractor : JGC Arabia Ltd.

4.6 PMT : Saudi Aramco Project Management Team

4.7 CQCI : Civil Quality Control Inspector

4.8 CQCE : Civil Quality Control Engineer

5. RESPONSIBILITIES

5.1 The Civil Supervisors in-charge shall be responsible for the following: -

To ensure construction is carried out to the required Job Specifications.

When the work is ready for inspection then raise the internal Application for Inspection form.

To ensure that all parties required making any kind of inspections or tests are suitably informed as to the construction program.

To ensure that the required number of samples are taken from each source of fill for the evaluation of fill materials.

5.2 The Quality Control Manager shall be responsible for the following: -

Review all relevant documentation & test reports and prepare all Handing over Dossiers and clear out all Non Conformances.

Ensure that all other discipline activities that must be inspected within the Earthworks construction program has been inspected and cleared.

Organize and allocate inspection works to the Quality Control Inspectors.

5.3 The Civil Quality Control Inspector shall be responsible for the following: -

Organize Inspection Requests as per the required Construction priorities.

Inform JGC and Company representatives by the official Inspection Request form, as and when their presence is required to carry out Inspections.

Accompany JGC and Company representatives to carry out Inspections and release hold points.

Sign and obtain signatures from Contractor / Company representatives on the various Inspection & Test Plans (ITPs), as required.




QCP-795-210 Rev. 1

5.4 The Lab Technician shall be responsible for: -

Sampling & conducting field testing.

Issuing and reviewing all Laboratory results reports required

Evaluation of the suitability of the soil materials involved in the work

5.5 The Technical Clerk shall be responsible for: -

Keeping daily log of all Inspection Forms Requests submitted by the Civil Supervisors in-charge.

Filing & compiling all inspection records and Handing Over Dossiers under the supervision and instructions of the Quality Control Manager.

6. PROCEDURE

6.1.1 Excavation

The Site or Section Engineer shall be responsible for checking and performing the Pre-excavation activities prior to allowing excavation to proceed.

6.1.2 General Excavation

General excavation shall be performed after clearing and grubbing has been completed in accordance with PIP CVS02100, Section 6.

6.1.3 Structural Excavation

6.1.3.1 Structural excavation shall include excavations for footings, grade beams, pits, basements, retaining walls, man holes, catch basins, etc.

6.1.3.2 Excavation shall be performed as required by the design drawings to the dimensions, grades, and elevations as noted and as required for formwork.

6.1.3.3 When soft and compressible soil is encountered at footing grades as shown on the drawings, such soil shall be removed and replaced with compacted fill or backfill as specified in SAES-A114, Sections 6.2 and 6.3.2.

6.1.3.4 Over-excavation at footings may be backfilled with lean (2000 psi minimum 28-day compressive strength) concrete.


1



QCP-795-210 Rev. 1

6.1.4 Earthen Structures

Earthen structures include permanent work items such as ponds, canals, ditches, etc. Excavation for such work shall be made to the lines, grades, and cross sections as shown on the drawings.

6.1.4.1 Side slopes of excavations shall be cut true and straight and shall be graded to the proper cross section. Unstable soil in the slopes shall be removed and the slopes properly prepared. The bottoms of excavations shall be graded to the elevations and configurations as shown on the drawings.

6.1.4.2 Over excavation shall be backfilled with suitable material and compacted in accordance with SAES-A114, Section 6.3.2.

6.1.5 Disposal of Materials

All excavated materials that are unsatisfactory for use as fill or backfill or that are surplus to that needed for backfilling shall be disposed of at a location designated by Saudi Aramco.

6.2 Evaluation of Suitability for Sub-base, Road Base & Fill Material.

6.2.1 Fill material for embankment works.

Evaluation of imported material for embankment works shall be as defined in SAES-M-100.

6.2.1.1 Testing: When samples are tested, the material should be classified as select/general fill material.

6.2.1.2 Application Procedure:

a. Place fill material in horizontal layers not exceeding 200 mm in loose thickness.

b. For fill less than 3820 cubic meters (5000 cubic yards) at least one in place density test should be made for every 382 cubic meters (500 cubic yards) of compacted soil.

c. For fill in excess of 3820 cubic meters (5000 cubic yards), at least one in place density test should be made for every 1530 cubic meters (2000 cubic yards) of compacted soil.

d. For footing subgrade - for each stratum of soil on which footings will be placed, conduct at least one test.

e. At least 95% of the maximum dry density should be achieved for any compaction test at site.

6.2.2 Fill material for underground services shall be defined in:

SAES-S-070 clauses 7.0, 9.0 & 21.0.


1



QCP-795-210 Rev. 1

6.2.2.1 Testing: When samples are tested, the material should be classified as:

a. General/structural fill/select fill.

b. Clean sand for bedding and cover.


a. Place backfill in horizontal layers not exceeding 150 mm in loose thickness to the tops of all piping, culverts and electrical cables.

b. Above the tops of all items, place the fill in layers not exceeding 200 mm in loose thickness.

c. Within 300 mm of the top of the pipe, backfill shall be hand tamped, or aboard shall be used to protect the pipe from damage from vibratory plate compactors.

d. Compact each layer up to at least 95% of the maximum dry density or 70% relative density.

6.2.3 Granular sub-base and base course road shall be as per SAES-Q-006.

6.2.3.1 Testing: When samples are tested, the material should be classified as per SAES-Q-006, Tables 6 & 7.


a. Place fill material for base course and sub-base shall be placed in layers not exceeding 150 mm after compaction.

b. Provide compaction properly by suitable means of compactors/rollers.

c. At least one field density test should be made for each 2000ft2 (180m2)

d. The compaction should be not less than (100% for the base and 95% for the sub base) of the maximum density.

6.2.3.3 Test results shall be recorded on form FM-795-2101. Form FM-795-2101 is a generic form, to be filed sequentially, and not with individual ITPs. The ITPs that utilize form FM-795-2101 will reference the applicable Serial No. of this form on the ITP.

Note :- No material shall be hauled to the site until it has been cleared as suitable for its purpose.

6.3 Inspection & Testing of Compacting Operations.

6.3.1 Backfill and Compaction

The Civil Supervisors in-charge shall initiate form FM-795-2102 (Section 1), and pass it to the Civil QC Department to request inspection of fill placement.

The CQCI will check to confirm that all required releases for the area are properly signed on the relevant ITP’s (if applicable).

The CQCI will inform the Lab. Technician to perform field density tests as specified in ITPs.


1



QCP-795-210 Rev. 1

The Lab. Technician shall test and report compaction test results on Form FM-795-2102 (Section 1).

No further backfilling shall be permitted until the lift has been cleared by the CQCI, based on the compaction test results presented by the Lab. Technician.

The Lab. Technician shall retain form FM-795-2102 and continue to document compaction test results for subsequent lifts in the same area until the last layer is tested. He shall then sign form FM-795-2102.

The CQCI, shall review the completed form FM-795-2102 and if all test results are conformant, shall then sign the relevant ITPs (if applicable), releasing the area for all other activities.

6.3.2 Natural ground Stabilization

After the completion of the excavation and proof rolling, the Section or Site Engineer will initiate and submit to the QC Dept. form FM-795-2102 (section 2), to request inspection of Natural Ground Stabilization.

The CQCI, upon receipt of form FM-795-2102 shall perform surveillance inspection of the area of Natural Ground Stabilization and sign the form if all items are conformant. He shall then sign the relevant ITP (if applicable), releasing the area for other activities.

6.3.3 Testing Frequency & Passing Criteria for Compaction Operations

For Ground Stabilization, General Fill & Embankment works as per SAES-M-100 & SAES-Q-006.

For Sub-grade and Base course Layers, as per SAES-M-100 & SAES-Q-006.

For Backfill over Underground services, as per SAES-S-070.

6.3.4 Documentation

Form FM-795-2102 is a generic form to be filed sequentially and not with the individual ITPs. The ITPs that utilize FM-795-2102 will reference the applicable Report number of this form on ITPs.

7. ATTACHMENTS

7.1 FM-795-2101 : Evaluation of in-situ Fill Material

7.2 FM-795-2102 : Earthworks Compaction Record.


QCP-795-210_1

Documents

Transcript of QCP-795-210_1