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I
THERMAL AND
DATE OF ISSUANCE
PREVIOUS REVISION NO.&DATE OF ISS
PREPARED BY
NAME Mark Santana
TITLE KPC-QA
DATE 21/10/2010
SIGNATURE
SLEVEL 3DOCUMENTSSTATEMENT OF METHOD
ATER CURING OF DRAIAND COVER SLABS
MSCODE NO.:KPC-014-PRD-007
REVISION :00
: 21OCT 2010
UANCE : N/A
ISSUED TO
Bechtel Overseas, Inc.
N CHANNELS
PROJECT /CLIENT
aaden Aluminum Smelter
Plant Project
140
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1.0Title2.0Methodology
2.1General Description2.2Equipment2.3Materials2.4Preparation2.5Work & Methodology
3.0Quality Assurance3.1Contractual Requireme3.2Responsibility3.3Inspection & Testing
4.0Safety & Health4.1Protective Safety Equip4.2Environmental Safety4.3MSDS4.4Risk Assessment
5.0References6.0Figures7.0Attachments
7.1Heater Specifications7.2Thermocouple Specific7.3Forms
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
TABLE OF CONTENTS
nts
ment
Health Contractor Requirements
ations
Page 2 / 23
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1.0 TITLESteam and
2.0 SCOPE OF WORK2.1 GENERAL DESC
This docum
for Maaden Alumi
Overseas, Inc. is th
for manufacture ancompliance with th
Curing is de
temperature in con
(ACI 116R-90).
KPC will app
a. ThermalDB00-0Using R
while th
strippin
b. Water Csupple
area in t
Applicable
quoted and followe
2.2 EQUIPMENT
List of Equip
A. For1.
-
--
-
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
ater Curing of PC Units
IPTION
nt outlines the procedure for Thermal and
um Smelter Plant Project in Jubail, Kingdom
Main Contractor and Al Kifah Precast Com
d delivery of required Precast Concrete Unitis procedure.
fined as the maintenance of satisfactory moi
crete during its early stages so that desired
ly two-stage curing system as follows:
Curing as described in Bechtel Specification
01. Thermal Curing corresponds to Acceleradiant Heat and Moisture (PCI-MNL-116, Se
e PC Units are in the mould inside the Facto
, release and lifting strength of concrete at
uring which is curing by moisture retention
ental heat. This is done after the units are t
he Stockyard.
echtel Specifications and Industry Codes pe
d.
ment:
hermal Curing
eaters / Blower (see Sec. 7.0, Attachments)
PC to use Heaters with the following specifi
Brand : Dimplex Model No. CFH90
Max. Temp. = 55CHeat Output = 9.0 kW
Noise = 60 dB
Page 3 / 23
ater Curing of PC Units
of Saudi Arabia. Bechtel
any is the sub-contractor
s and responsible for
sture content and
roperties may develop
No. 25457-0000-3PS-
ted Curing of Concrete. 4.21.3). This is done
y to achieve the required
n earlier time.
ithout the use
ansferred to designated
taining to the subject are
ations:
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-
-
-
2.3.4.5.6.7.
B. For1.2.
2.3 MATERIALSNo mate
2.4 PREPARATIONPrior app
achieved the req
3PS-DB01-0001
Time, which sho
Concrete Compr
2.5 WORK METHOA. Acceler
Curing):
1. Afteare
unif
2. Rubway
the
burl
dist
3. Cubpare
4. Mon
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
Airflow = 900 m3/h
Throw = 10m
Temperature Control with Built-In Thermosased on settings
lectronic Surface Thermocouples, with Pins
ttachments)
adiator, Fan (for Air Circulation)
ollowcore Bed Water Heating Pipes (Option
hermometer
ubberized Tarpaulin
xpanded Polystyrene
ater Curing
essian Cloth / Burlaps
pproved Water Source
ials required.
lication of heat for thermal curing, ensure th
uired initial setting time as per Bechtel Spec
Furnishing & Delivering Ready Mix Concret
uld not be in any case less than 1 hour and a
essive Strength achieved 3.4 MPa (500 psi).
OLOGY
ted Curing of Concrete using Radiant Heat a
ensuring that the concrete has achieved th
laced and arranged in such a way that all ar
rmly (see Section 6.0, Fig. 1 & 2).
erized Tarpaulin and Expanded Polystyrene
that the units are thoroughly covered and m
ontraption. Moisture is maintained using a
p/hessian cloth. Double the thickness at co
nce of 300mm.
Samples for Compressive Tests should be c
nt concrete.itor the interior and surface temperature of
Page 4 / 23
at, Automatic Adjustment
(see Sec. 7.0,
al)
at the concrete had
ification No. 25457-0000-
Sec. 3.3 Initial Setting
s determined by the time
nd Moisture (Thermal
e initial set, the heaters
eas will be heated
to be installed in such a
inimal heat escapes from
over of moist
ners and edges for a
ured the same way as the
the unit using embedded
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ther
leas
inteinst
instr
the
redu
5. Mea6. Tem
a.b.
c
c.t
d.
e.s
t
f.c
t
c
g.t
t
h.r
(
7. Thewat
B. Water C
1. AppWat
2. Thormini
3. Dou
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
ocouples tied to a continuous logging and
2 thermocouples (one as spare) in the locat
nal temperature is expected (generally thell thermocouples on each exposed face of t
uments at mid-point of the cover zone. As e
ehavior of the mix, the total number of sur
ced to two.
sure ambient air temperature using thermo
perature Control (see Section 6.0, Fig. 3)
re-Heat Temperature should be set at Ambi
hour (+0.33C/min).
cquire Temperature Readings every 30 min
losely monitor the differential temperature.
nit should have a temperature difference o
aintain the rate of adding 20C per hour un
he maximum allowable temperature at 65
djust the setting of heaters as necessary. A
er actual condition. Localized Hot Areas s
eating Pipes may be used to adjust the hea
ecessary
aintain the temperature at 65C and monit
ntil the required stripping and lifting streng
trength is equal to 60% of the design concre
he Materials Engineer.
llowable cooling rate is at -28C per hour (-
ontinue until the concrete temperature is n
he ambient temperature outside the enclos
racking.
emove insulation in stages in such a way th
emperature differential is not exceeded (20
emperature is within 10C of Ambient Temp
ubsequent monitoring of heating of precast
educed to every 3 hours (for Pre- and Heati
for Cooling Cycle) upon a clear demonstrati
nd other damage were incurred during first
moulds are stripped and moved to designat
r curing.
uring
oved units are transferred to designated ar
r Curing.
oughly cover individual units with pre-satur
mum of 2 layer hessian cloth.le layer polythene sheet is not required if t
Page 5 / 23
recording system. Install at
ion where the maximum
ass center). Initially,e element. Install these
perience is gained as to
ace thermocouples may be
eters.
ent Temperature +20C for
tes at this stage, and
No two portions of the
more than 20C.
til the concrete reaches
.
d or remove heaters as
ould be avoided. Bed
ing uniformity as
or every 1 hr if first time
h is achieved. Lifting
te strength as directed by
.50C/min). Cooling must
more than 22C above
re to prevent surface
t the maximum allowable
C), and until the surface
erature.
concrete units may be
g Cycle) and every 6 hours
n that no thermal cracks
3 batches of units.
d area in Stockyard for
a in the Stockyard for
ted hessian cloth. Use
e units are thermal-cured.
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4. Watconc
5.
Watthor
the
6. No c7. Wat8. Insp
dryi
9. If dr
3.0
QUALITY ASSURAN3.1 CONTRACTUAL
1. Acce000
Spec
014-
2. Becrepo
whil
3.2 RESPONSIBILIT
The foll
Procedure:
1. Ther2. Wat
Stoc
3.
InspSup
4. DocSant
5. InspEngi
3.3 INSPECTION &1. Freq
inte
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
r used for curing must be the same water u
rete.
r is manually sprinkled until the hessian clooughly wet. Water curing will be considered
oncrete surface is damp to touch.
uring compound should be used.
r curing should be for seven (7) consecutiv
ct curing minimum twice at daytime and on
g. Replenish water as required.
ing is discovered, re-wet and increase the i
E
REQUIREMENTS
ptance criterion will be based on Bechtel Sp
-3PS-DB00-0001 Concrete Work and othe
ifications and Inspection and Test Plan Po
ITP-011.1.
tel Resident Engineer or his representative
rt on daily basis. The Bechtel Resident Engin
the inspection is being conducted.
wing personnel are responsible for the con
mal Curing: Ramesh Lama Production Engi
r Curing: Ferdinand Gurion / Eduardo Sison
kyard
ction: Alfred Comendador QC Engineer, Frvisor, Alfred Carpio QC Supervisor
ment Control and Review: Alfred Comenda
ana IMS-MR
ction and Document Review: Vinod Kannat
eer
ESTING
uency
Frequency of measurement within the un
vals specified in the Work Methodology.
Page 6 / 23
sed for the production of
h and the precast unit issatisfactory if at any time
days.
ce at night for signs of
spection frequency.
ecification No. 25457-
r relevant Bechtel
t-Pour Inspection (KPC-
ust be given a copy of
eer may also be present
uct of this Operational
neer
Production Engineer,
eddie Toledana QC
or QC Engineer, Mark
- Bechtel Resident QC
it must cover all units at
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2. Equiuse:
a.b.
usin
3. RecPoin
Co
The
W
Cal
Re
Con
to B
repr
4.0 HEALTH & SAFETY4.1 PROTECTIVE &
The followi
personnel conducti
1. Hard
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
pment
All measuring equipment must be thorou
hermocouple must be calibrated by duly-
gency.
hermometers - must be calibrated by duly-
gency.
Heat/Blowers need not to be calibrated,
above mentioned instruments.
rds
The following Forms must be used on eac
ts:
Quality
trol Point
Form Form Code
No.
Prep
rmal Curing
Post-Pour
Inspection
Report
KPC-014-F-
QAC-034Eac
ter Curing
Post-Pour
Inspection
Report
KPC-014-F-
QAC-034Eac
ibration of
easuring
Devices
Calibration
of
Equipment
KPC-014-F-
QAC-026
Upd
re
porting of
Non-
formance /
CAPA
NC and
CAPA Log
Sheet
KPC-014-F-
QAC-032
Eac
Con
Records shall be kept in KPC QC Departm
chtel Resident Engineer duly noted by KPC
sentative.
KPC QA/QC Department copy is kept for
SAFETY EQUIPMENT
g are the list of Personal Protective Equipm
ng this activity:
Hat
Page 7 / 23
ghly inspected prior to
pproved calibration
pproved calibration
ut performance measured
h specified Quality Control
aration ITP Reference
Code
h Unit
Post-Pour
Inspection (KPC-
014-ITP-012.1)
h Unit
Post-Pour
Inspection (KPC-
014-ITP-012.1)
ated as
uired
Calibration of
Equipment (KPC-
014-ITP-014.1)
h Non-
ormity
Quality
Management
System (KPC-014-
ITP-000.1)
ent and copies distributed
C Engineer or his
inimum of two (2) years.
nt to be used by
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2. Safe3. Cott
4.2 ENVIRONMENPersonal Pr
4.3 MSDS (MANUFNot Applica
4.4 RISK ASSESSME
Not Applica
5.0 REFERENCESBechtel Specificati
Revision 00
ACI 116 R-90 Cem
American C
PO Box 909
Manual for Qualit
Products, 3rd
Editio
Precast/Pre
175 West Ja
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
ty Shoes
on Gloves
AL SAFETY & HEALTH SUB-CONTRACTOR R
tective Equipment
CTURER SAFETY DATA SHEET)
le
NT
le
n No. 25457-0000-3PS-DB00-0001 Concret
, 07 May 2010
nt and Concrete Terminology
ncrete Institute (ACI)
, Farmington Hills, MI 48333-9094
y Control for Plants and Production of Stru
n PCI Manual MNL-116,
stressed Concrete Institute (PCI)
ckson Blvd., Chicago, Illinois 60604
Page 8 / 23
QUIREMENTS
e Work
tural Precast Concrete
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6.0 FIGURES
Fig. 1: Heater and Mould Assembl
For Drain Channels (may be modi
as per actual conditions). Note th
movement of air through direct
heater blower throw (10m) and
subsequent heat movement throu
convection.
HEATED AIR
MOVEMENT
THROUGHCONVECTION
(SAME AS ON
UPPER PORTION)
STEEL SHEET (TO
AVOID DIRECT
HEAT THROW
COLLISION BUT
TRANSFER
RADIANT HEAT)
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
ied
gh
HEATER
HEATER
DIREC
THRO
Page 9 / 23
T HEAT
W
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0
10
20
30
40
50
60
70
80
90
100
Fig. 2: Heater and Mould Asse
heating a
Fig. 3: Thermal Curing Tempe
illustrative purposes only; ac
Pre-Heat @
+27C/hr
C
TIME Variable:
Ambient - Peak
Temp.
Time
HEATER
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
mbly for Cover Slabs. Bed Heating Pipes are
nd temperature controlled at the Boiler Roo
rature and Concrete Compressive Strength
tual conditions may vary but must not exceedocument)
Sustained
Heating
Cooling
@ -28C/hrWater
Thermal Curing Stage
TIME Variable:
60% Conc.
Strength
TIME Variable:
Peak - Ambient
Temp.
Page 10 / 23
Concrete Strength
Curing Temperature
sed to ensure uniform
m.
elationship (Note: for
d the limits set in this
Initial Setting Time
Initial Ambient Temp.
Peak Temp. @ 65C
Conc. Lifting Strength
Curing Stage (7 Days min.)
ater Curing Stage
DIRECT HEAT
THROW
BED HEATING
PIPES
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7.0 ATTACHMENTS7.1 HEAT BLOWERS
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System Page 11 / 23
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METHOD STATEMENT
Management System Page 12 / 23
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7.2 SURFACE THERMOCOUPLE
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System Page 13 / 23
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METHOD STATEMENT
Management System Page 14 / 23
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METHOD STATEMENT
Management System Page 15 / 23
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METHOD STATEMENT
Management System Page 16 / 23
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METHOD STATEMENT
Management System Page 17 / 23
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8.0 FORMS8.1 CONCRETE POUR C8.2 POST-POUR INSPE
8.3 CALIBRATION OF E
8.4 NC AND CAPA LOG
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
Management System
ARDTION REPORT
UIPMENT
SHEET
Page 18 / 23
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METHOD STATEMENT
Management System Page 19 / 23
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METHOD STATEMENT
Management System Page 20 / 23
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METHOD STATEMENT
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METHOD STATEMENT
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ll d d
ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS
METHOD STATEMENT
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