CONCRETE LABORATORY PROCEDURE

Title: Preparation and Management of Concrete Laboratory Procedure Procedure Number: 9-077-L-578-000
Purpose Requirements of preparation, revision and management of procedure for standardization Applicability Applied to affairs concerning preparation, review, approval, revision, distribution, and abolishment of UAE BNPP laboratory procedure References and General Requirements KEPCOs Quality Assurance Manual KEPCOs Site Internal Procedure for UAE BNPP UAE BNPP Quality Assurance Manual Nuclear Quality Assurance, Test and Inspection Concrete quality test procedure Application of all technical specification and standard Terms and Definitions Evaluation of Effectiveness Responsibility Project Manager to be called Laboratory Manager Responsibility for operating laboratory Establishment and approval of project procedure Training plan and development of training material Concrete Inspection/Test Personnel Preparation, review, revision and distribution concrete lab. procedures Test and management affairs Calibration and maintenance of equipment Procedures Preparation Tile and serial number Contents of procedure Review and Approval Reflect reviewers comments Approval of Laboratory Manager Revision of Procedure Initial preparation of procedure Revision number of procedure Evaluation of effectiveness of procedure

Appendix Procedure cover Procedure revision history Evaluation of procedure effectiveness Comprehensive list of procedure record Provision revision summary

Title: Indoctrination/Training and Qualification of Concrete Inspection/Testing Personnel Procedure No: 9-077-L-578-001

Purpose Requirements and procedure for indoctrination/training and qualification of concrete inspection/test personnel Applicability concrete inspection/test personnel working for UAE BNPP Site concrete inspection/test personnel working for Hyundai Samsung Joint Venture (HSJV) performing concrete and other tests for UAE BNPP site (inspection/test items may be limited for each Level)
Responsibility Director of Construction Material Engineering Division Project Manager( Site Representative/Chief Laboratory Engineer/Laboratory Manager) Personnel in charge of qualification management Procedure Qualification o ELEMENTARY INSPECTOR (LEVEL I) Education: At least 2 years of engineering or science study and 3 months of experience in concrete inspection/testing; or high school graduate, 6 months in concrete inspection/testing, 30-hr theoretical education and 20-hr OJT Responsibilities: Tests on Concrete, Aggregate, Re-bar and Cad-welding, Non-shrinkage Grout, Cement, Ground Granulated Blast-furnace Slag (GGBS), Silica Fume, Mixing water and Admixtures o INTERMEDIATE INSPECTOR (LEVEL II) Education: (a) Graduate of at least 4-year engineering or science degree, 6-month experience in concrete inspection/testing, 15-hr theoretical education and 10-hr OJT; or (b) At least 2-year experience in engineering or science study, 1-year experience in concrete inspection/testing, 30-hr theoretical education and 10-hr OJT; or (c) High school graduate, 2 years of satisfactory performance as Level I Inspector, 45-hr theoretical education and 10-hr OJT Responsibilities: Aggregate Test, Ground Granulated Blast-furnace Slag (GGBS), Blended Cement, Concrete Production Inspection/Testing, Witnessing of soil tests in main facility projects, Preparation of Quality Inspection/Testing procedures, and other related tests which may be deemed necessary by Level III Concrete Inspector o ADVANCED INSPECTOR (LEVEL III) Education: (a) At least 2 years of engineering or science study, a Professional Engineer with experiences of 7 years in construction work, 2 years in NPP construction, 9 years in inspection/testing, 6 years in concrete inspection/testing, 20-hr theoretical education and 10-hr OJT; or (b) A graduate of at least a 4-year degree in engineering or science, a Professional Engineer with experiences of 7 years in construction work, 2 years in NPP

construction, 5 years in inspection/testing, 3 years in concrete inspection/testing, 10-hr theoretical education and 10-hr OJT *Note: in case of lack in experience in inspection/testing, it may require two times the shortage period in NPP construction or at least 6 years (for option a)/ 3 years (for option b) in concrete inspection/testing. Responsibilities: Concrete Production Inspection/Testing, Quality Inspection/Testing, Education/Training for Certification, and Soil tests for main facility projects o OTHER REQUIREMENTS A candidate shall have a vision (eye capacity) capable of reading J-1 letters, 20-40 by Linear Snellen Scale, and capable of color vision. He shall also be able to clearly judge and identify his responsibilities and scope in a given task. Physical examination shall be held at a private/general hospital or site clinic. Indoctrination/Training o The evaluator shall design training programs and designate training personnel for each level of candidate. Level II Inspector, or higher, shall train Level I candidate while Level III Inspector shall train Level II or Level III candidate. When important engineering skill/technique is required, an external specialist may be designated. o The training personnel shall prepare practical implementation, oral and written tests for candidates. o In oral tests, Level I candidate shall be able to answer more than 10 questions while Level I and II candidates shall be able to answer more than 20 questions. Pass score shall be over 80 points for all levels. o In written tests (maybe a combination of objective, subjective, and true-or-false questions), all candidates shall be able to answer more than 20 questions. Pass score shall be over 80 points for all levels. Test time shall be 1 hour per 20 questions.

Qualification Certification and Re-certification o The evaluator shall submit to the Director of Construction Material Engineering Division, Qualification Review Document of Concrete Inspection/Testing Personnel. This shall contain the training program, training attendance sheet, qualification evaluation, written test sheets, certificates of educational and experience career, physical examination records, and other relevant documents. o The Director of Construction Material Engineering Division shall issue a Certificate to a candidate who has satisfied all requirements. The Level III Inspector shall prepare, maintain and record certificates issued. o The certificate is valid for 2 years and upon expiry, it shall be reviewed whether recertification is necessary. o A personnel who has not performed inspection/test for 1 year shall lose certification and shall be re-certificated through the same procedure for initial certification. However, he may be re-certificated without indoctrination if he has actual result of inspection/testing task for

1 year or more, completed technical training and OJT, and satisfied physical examination and capability. The Evaluator (Level III Inspector) shall review re-certification, prepare re-certification document, submit it to the Chief of Construction Materials Engineering Department who shall review it, re-certify, and notify the QS Team Manager of UAE BNPP Site. The Evaluator shall, at the beginning of every year, implement an OJT program for maintenance of certification of inspection/testing personnel.

Title: Concrete Laboratory Testing Management Procedure No: 9-077-L-578-002

Purpose Relevant and applicable codes/standards and laboratory management requirements for testing and quality inspection during concrete production Applicability Management of material testing, inspection and calibration performed in the Concrete Laboratory Responsibility Technical/Engineering support Project Manager/Site Manager/Chief Laboratory Engineer/Laboratory Manager Concrete Inspection/Testing Personnel KEPCO Manager of QS Team of BNPP KEPCO QS Personnel of UAE BNPP Procedure Condition of Laboratory Environment o Cement test room Temperature: 20-27.5C; Relative Humidity: not less than 50% o Concrete specimen fabrication room Temperature: 16-27C (20-26C for 6,000 psi or more compressive strength) o Concrete curing room Temperature: 21-25C; Relative Humidity: not less than 95% Testing Management of Cement GGBS and Silica Fume o Cement Sample to be taken upon delivery: approximately 20 lb for every 1200 ton (15 lb for testing; 5 lb to be stored in the laboratory until relevant amount is consumed at least within 3 months) Testing items, methods, and frequencies are shown in Table 1 o GGBS Sample to be taken upon delivery: approximately 20 lb for every 2500 ton (15 lb for testing; 5 lb to be stored in the laboratory, in a tightly closed container with sample no. and sampling date attached, until relevant amount is consumed at least within 3 months) Testing items, methods, and frequencies are shown in Table 1 o Silica Fume Sample to be taken upon delivery: approximately 10 lb for every 110 ton and 440 ton (7 lb for testing; 3 lb to be stored in the laboratory, in a tightly closed container with sample no. and sampling date attached, until relevant amount is consumed at least within 3 months) Testing items, methods, and frequencies are shown in Table 1

The Laboratory Manager shall review the CMTR submitted by the supplier and shall witness, if required along with KEPCO QS Personnel, the tests done at suppliers factory o The Concrete Inspection/Testing Personnel shall measure the temperature of cement at shipment and attach sample no. He has the authority to reject materials that has one or more of the following: When any of the documents submitted is missing When the CMTR does not comply with the requirements of purchase When there is external cracking or moisture intrusion When test results do not conform to requirements ( Tests shall be done within 3 days upon shipment) When actual quantity is lesser by 2% or more for cement, and by 5% or more for GGBS Testing and Quality Control of Coarse Aggregate and Fine Aggregate o Test items, methods, and frequencies are shown in Table 2 o Petrographic Examination and Potential Alkali Reactivity shall be tested by external accredited (3rd party) laboratory. Testing and Quality Control of Mixing Water (including water to be used for making ice) o Test items, methods and frequencies are shown in Table 3. o Chloride Ion Content test may be done by an external accredited laboratory. Testing and Quality Control of Admixtures o The admixtures delivered shall conform to CP-C2 Specification. The Laboratory Manager shall review the CMTR and, if needed, shall send a copy to concerned Department. o Test items, methods and frequencies are shown in Table 4. o CMTR shall contain tests on specific gravity, residue by oven drying, infrared analysis, physical tests, and chloride content for both High Water Reducing Admixture (HWRA) and Superplasticizer. Testing and Quality Control of Non-shrink grout o Initial and control test items, methods, and frequencies are shown in Table 5. Concrete Production Inspection and Testing o Concrete mix design, sampling and testing shall be in accordance to CP-C2. At least 30 consecutive compressive strength tests shall be done to determine whether a revision is needed. o Test items, methods and frequencies are shown in Table 6. o A retest shall be done on another portion of concrete sample when one of the tests does not satisfy requirements. If the test result is still not satisfactory, the Testing Personnel shall write down REJECT on the Batch Ticket. Strength Test o The compressive strength test equipment shall be operated only by certified personnel. The concrete specimen shall be tested by capping both sides or with un-bonded pad cap. It shall be loaded until breakage. o The cubical specimen of grout, drypack and mortar shall be tested in accordance to ASTM C 109

The rebar specimen (or other reinforcements) shall be stored (24 hr min) until it reaches room temperature. Length: minimum 12 in, maximum 40 in Requirements of Testing Machine Load Capacity: 600,000 lbs; Grip Range: Max #18 Rate of loading Maximum of 30,000 psi any convenient speed of testing 30,000 psi-maximum load 10,000-100,000 psi/min Tensile Strength Maximum load (lb)/original cross-sectional area (in2) Inspection and Testing of Concrete Production Facility o The Laboratory Manager and Inspection/testing personnel shall be in-charge of the inspection and supervision of concrete production at Batch Plant. o The Inspection/testing Personnel (B/P Inspector) has the authority to reject a batch of concrete produced inappropriately. Concrete Production Inspection o The B/P Inspector shall perform inspection using Batch Plant Inspection Checklist. Management of Test Data o Test results shall be managed using the NPCMS system.

Title: Calibration Management of Concrete Testing Equipment and Measurement Tool Procedure No: 9-077-L-578-003
Purpose Calibration procedure for reliability and precision of measuring and test equipment (M/TE) Applicability M/TE or test apparatus in the Concrete Laboratory Responsibility Project Manager/Site Manager/Chief Laboratory Engineer/Laboratory Manager Test Apparatus Calibration Personnel Procedure Internal Calibration o Shall be done by an internal calibration inspection/testing personnel o If an item is out of calibration, a Usage Hold tag shall be attached to it, and it shall be isolated. The cause shall be assessed, and the item shall be repaired, re-calibrated, or the manufacturer shall replace the item with another that is calibrated. o Items to be calibrated, calibration methods and frequency are shown in Table 1 o calibrated apparatus shall have calibration identification tag External Calibration o Shall be done by an internationally accredited calibration agency o If an item is out of calibration after delivery, a Usage Hold tag shall be attached to it, and it shall be isolated. The cause shall be assessed and repair/re-calibration/disposal shall be performed o Items to be calibrated and frequency are shown in Table 2 o Calibrated apparatus shall have the tag of calibration agency If a test apparatus, while being used in the laboratory, is out of calibration more than once, the interval of frequency may be reduced to ensure reliability. If a test apparatus is out of calibration more than 5 times, it shall no longer be used Test apparatus that does not require calibration (according to KRISSs calibration frequency table) shall have a Calibration unrequired tag Certificate no. of internal calibration shall be expressed in the following manner: Abbreviation of Calibration (Numerical digits of Control No.) Last 2 digits of calibration year Calibration sequence no. of each apparatus per year

Title: Sampling and Subsampling/ Reduction of Concrete Materials Procedure Number: 9-077-L-578-004

Purpose Describes subsampling/reduction procedure for quality testing of concrete materials. Applicability Covers sampling and subsampling activities of concrete materials References and General Definitions UAE BNPP concrete production specification UAE BNPP quality assurance manual KEPIC QA ASME NQA-1200 ASTMC702 ASTMD75 ASTM C 183 ASTM C 494 Terms and Definition Sampling Subsampling/Reducing Grab Sampling Composite Sampling Responsibility Project Manager-Laboratory Manager Concrete Inspection/Testing Personnel Procedure Sampling Aggregates Stockpile Sampling from Batch Plant Bin Specimen Collection at Belt Conveyer Sampling Aggregates Mechanical Splitter Method Quartering Method Sampling Cement, Silica Fume and GGBS Physical/chemical testing according to ASTMC 150 Remaining sample shall be kept in a container with sample number Admixtures Shall be obtained every shipment from the admixture tanks Testing shall be performed according to ASTM C 494, or ASTM C 017 Shipping Samples and Identification Method Individual identification shall be attached Sample container must not easily deteriorated Silica fume or GGBS shall be stored differently

Appendix Sample Identification Label (9-077-L-578-004-001)

Title: Procedure for Health, Safety, and Environment of the Concrete Laboratory Procedure Number: 9-077-L-578-005

Purpose Describe the Health, Safety, and Environment of testing personnel Applicability Applies to health and safety for the testing personnel who perform test of concrete References and General Requirement HSE Procedure Laboratory Safety Terms and Definition Health, Safety, and Environment procedure Material safety data sheet Responsibility Laboratory Manager Analysis of risk factor Understanding of the actions to be taken General training relating HSE Approval of HSE procedure Person in charge of HSE in the laboratory Preparation, revision, and maintenance Taking HSE education Procedure General Testing personnel shall pay attention to HSE Material safety data sheet Make testing personnel take HSE education Restricted area to unauthorized person Fire extinguisher shall be furnished in each laboratory Safety Rules in Laboratory Methods how to handle and use chemicals Methods how to handle high-temperature/high-pressure test equipment How to handle glassware Strength test of re-bar and concrete Other material test Safety Rules of Field-Test Testing personnel shal wear the protection devices Personal protection devices Safety rules relating to field testing Movement by working or a vehicle Others

Appenixes Hazard diamonds Warning symbols Management log of testing chemicals Management log of waste matter

Title: Organization and DOR of Concrete Laboratory Procedure Number: 9-077-L-578-006 Purpose Address the direction and opinion delivery system for organization related to concrete laboratory Applicability Applied to DOR and authorities are clear defined for all personnel References and General Requirement UAE BNPP Terms and Definition N/A Responsibility Director of construction technology project Supporting the operation of concrete laboratory Laboratory manager Overall responsibility for management of concrete laboratory Procedure Organization Division of responsibility Laboratory manager Review and approval of concrete laboratory procedure Decision of DOR for personnel in the concrete laboratory Training and qualification of concrete inspection Approval of annual calibration plan of test apparatus Concrete Inspection Preparation of a procedure for the concrete laboratory Implementation of work in accordance with the concrete laboratory procedures Maintenance and management of test equipment Taking corrective action non-conformances Preparation of annual calibration plan Preparation of testing reports Maintenance and control of test records Appendixes Organization chart of concrete laboratory

Title: Control of Purchased Items for the Concrete Laboratory and Its Procurement Documents Procedure Number: 9-077-L-578-007 Purpose Establish and maintain the procedure to assure that the purchases related to work execution in the UAE concrete lab oratory are of appropriate quality Applicability Applied for purchased products service, purchasing, receipt, storage and maintenance References and General Requirements UAE BNPP Calibration management of concrete testing equipment and measurement tool Terms and Definition External calibration Procurement document Responsibility UAE BNPP Final acceptance of purchase request KEPCO QS Personnel of UAE BNPP Acceptance of purchase request Laboratory Manager Approval of documents produced by concrete laboratory Testing personnel Checking for quantity in demand of purchase Selection of appropriate supplier Receiving inspection of purchases Management of procurement document Handling and management of purchases Procedure Selection of supplier Consider the characteristics of the purchase item Purchase of items Based on the quotations obtained Purchasing order request shall be sent to the supplier For changes in purchase, the purchase request from that was already written should be revised Purchasing plan Inspection and receiving purchases Management of purchases Purchase shall be installed or kept in an appropriate place External calibration shall be performed Procurement document control Content of procurement documents Scope of service Technical requirement Quality assurance requirements Acceptance criteria Documentation requirements

 Procurement document review Shall be reviewed prior to issuance for bid to assure that necessary technical and quality requirements are included Procurement document changes Appendix Purchase request form Receiving inspection confirmation

Title: Management of Quality Document for Concrete Laboratory Procedure No: 9-077-L-578-008
Purpose Maintenance and documents for standardization and efficiency Applicability Distribution and disposal in the Concrete Laboratory Responsibility Project Manager /Site Representative/ Chief Laboratory Engineer/Laboratory Manager Concrete Laboratory Inspection/Testing Personnel Procedure Register the original copy of approved document in the document management list. The data controller shall copy the original document and record it in the Quality Document Management Log and shall send copies to the concerned department/s. When a revision is distributed, old version of documents shall immediately be disposed. Use of old version as reference may be done after it has been marked Unmanaged Document All test records in the laboratory shall be enrolled on NPCMS. After completion of laboratory work, they shall be transferred to the DDCC of KEPCO in UAE BNPP through computer network

Title: Identification and Management of Concrete Test Apparatus Procedure Number: 9-077-L-578-009 Purpose Specifies the requirements to prevent inappropriate use of items Applicability Identification and management of the concrete test apparatus References and General Requirements UAE BNPP Calibration management of concrete testing equipment and measurement tool Quality test procedure for KOLAS Terms and Definition Identification of item Responsibility Project Manager Approval of the procedure for identifying each test apparatus Testing Personnel Approval of the procedure for identifying each test apparatus Testing Personnel Identification marking Preparation of procedure Procedure Item identification marks Identification requirements for identification markings Item identification management Item shall be identified and traceable Items with limited life time shall be identified Detailed identification procedure shall follow equipment management procedure Appendix N/A

Title: Management of Nonconformities in the Concrete Laboratory Procedure No: 9-077-L-578-010 Purpose To ensure reliability by managing non-conformities in test results and test apparatus Applicability Non-conformities related to test work Responsibility KEPCO QS Personnel of UAE BNPP
Project Manager /Site Representative/ Chief Laboratory Engineer/Laboratory Manager Concrete Laboratory Inspection/Testing Personnel Procedure Test Results o The Testing Personnel shall notify the Laboratory Manager if a test result does not conform to the requirements. After review of the non-conformity, the Laboratory Manager shall attach a Usage Hold tag to the item and shall notify the QS Personnel by e-mail or Memo document. Test Apparatus o A test apparatus that is out of calibration or malfunctioning shall be notified to the Laboratory Manager and shall be isolated with a Usage Hold tag. It shall then be notified to the QS Personnel for NCR issuance. o A fixable apparatus shall be used after repair/correction/re-calibration o In case repair is impossible, the test apparatus shall be disposed of after approval of the Laboratory Manager and notification to the QS Personnel.

Title: Corrective and Preventive Action Procedure Number: 9-077-L-578-011 Purpose Prevent recurrence and other potential nonconformities Applicability Any corrective or preventive action against any nonconformities References and General Requirements UAE BNPP quality assurance manual KOCEN quality management procedure Terms and Definition Corrective action Preventive action Responsibility Project Manager Approval of request of corrective and preventive action Testing Personnel Planning, execution and result reporting Procedure Issuance of the request corrective and preventive action Testing personnel shall accomplish request of corrective and preventive action Analysis of causes Verification and analysis Review Implementation of corrective action Immediate corrective action shall be taken for adverse quality items Submit to senior for confirmation Post management Laboratory manager shall take the following preventive action to prevent recurrence Appendixes Request of corrective and preventive action Corrective and preventive action management log

Title: Management of Quality Procedures Procedure Number: 9-077-L-578-012 Purpose Address requirements for identification, index, reading, filing, storage, maintenance and disposal quality records Applicability Applied to both the quality documents/ records generated during the works References and General Requirements UAE BNPP quality assurance method Terms and Definitions Quality Record Responsibility Project Manager Final management of quality records Appointment of document controller Approval of records reading Testing Personnel Compilation and maintenance and management of quality documents Transfer to the DDCC or discard out of the date records in storage Transfer management for quality records Procedure Review and compilation of records Quality records shall be legible and identifiable and can be immediately searched Document controller shall understand and compile all quality documents Only the original document shall be compiled Index, Filing and Storage of records The compiled records shall be managed by records tittle of record separately The records shall easily be indexed by recording page or by attached label Storage, preservation and discard of records Must be stored in a facility equipped environment Managed by registering on NPCMS Shall always be kept at the designated place Shall be compiled by years of occurrence The quality of records shall fundamentally be preserved until the end of laboratory work In modifying records, testing personnel shall attach his signature or abbreviated form of name and record Appendix Document reading log

Title: Handling, Storage, and Shipping of Test Apparatus Procedure Number: 9-077-L-578-013 Purpose Describes the requirements for handling, storage, and shipping of test apparatus to be used for UAE BNPP concrete laboratory Applicability Applied to handling, storage and shipping of test apparatus to be used for UAE BNPP concrete laboratory References and General Requirements UAE BNPP quality assurance manual Identification and management of concrete test apparatus Management of nonconformities in the concrete laboratory Calibration management of concrete testing equipment and measurement tool Control of purchased items for the concrete laboratory and its procurement documents Terms and Definition Test apparatus Responsibility Project Manager Approval of procedure for handling Approval of maintenance and repair of test apparatus General management for handling, shipping and storage of test apparatus Testing Personnel Handling, storage, and shipping of test apparatus Checking of records matters of maintenance and repair of test apparatus Establishing procedure regarding maintenance and control of test apparatus Procedure Handling Apparatus controlled by the testing personnel after verification Shall be handled in accordance with the procedure Storage Shall be inspected and verified to meet the following environment conditions Shall be protected from rainfall Any potential cause of damage to the items in storage shall not be within the vicinity Temperature and humidity shall be so maintained not to cause damage Shall be kept clean Shall be managed through the test apparatus management card to check its condition Shall immediately reported to the laboratory manager if there are any doubts to the functionality and accuracy of the test apparatus Nonconforming test apparatus shall be stored separately attached with a usage hold tag Taking-out and Shipping Shall be taken out of the laboratory for its calibration or for other reason Shall utilize a suitable shipping container

Apparatus which requires special condition for moving shall be requested yo external specialized agency Management/ Control Test apparatus which do not conform the quality requirements shall be returned to the supplier for replacement Each test apparatus shall be given its own test apparatus number Appendix N/A

Title: Concrete Mix Proportioning Procedure No: 9-077-L-578-014

Purpose Mixture proportioning of ingredients for concrete production Applicability Selection of mixture proportions for hydraulic cement concrete made with or without other cementitious materials and admixtures Responsibility Project Manager /Site Representative/ Chief Laboratory Engineer/Laboratory Manager Concrete Laboratory Inspection/ Testing personnel (Level II) Concrete Laboratory Inspection/Testing personnel (Level I) Procedure Concrete mix classes and related matters shall comply with Table I of CP C2 D.7 Quality requirements of fresh mixed concrete for each trial mix o Slump Type B-1 Normal concrete: 4 0.75 inch Type A-1, B-2, B-3, & D High slump concrete: 6 0.75 inch Type C-1 High slump concrete: 5.25 0.5 inch o Temperature: 70 4 F o Density/Unit Weight Lean Concrete: Min. 137 pcf Structural Concrete: Min. 140 pcf Background Input Data o Fine Aggregate Fineness Modulus (FM) Bulk Specific Gravity (Density) in Saturated Surface Dry condition (SSD) Absorption o Coarse Aggregate Bulk Specific Gravity (Density) in Saturated Surface Dry condition (SSD) Absorption Unit Weight by Dry Rodded Method o Specific Gravity (Density) of Cementitious materials o Specific Gravity (Density) of Mixing Water o Specific Gravity (Density) of Chemical Admixture Sequence of Mix Proportioning (should be in accordance to ACI 211.1) o Required average strength, fcr Add 1,000 psi to fc = 2000 psi Add 1,200 psi to fc= 5,000 psi Add 1,400 psi to fc = 6,000 psi o Steps of Mixture Proportioning

1. Choice of slump 2. Choice of maximum size of aggregate 3. Estimation of mixing water and air content 4. Selection of water - cementitious materials ratio 5. Calculation of cement content 6. Estimation of coarse aggregate content 7. Estimation of fine aggregate content 8. Adjustment for aggregate moisture 9. Trial batch adjustment 10. Repeat step 3 to 9 if required o Fabrication of Specimen and Analysis of Strength Result When obtaining results in step 9, trial mixes with different water binder (W/B) ratio shall be proportioned based on the 1st trial mix. Concrete cylinders for testing shall be molded for each mix with different W/B ratio. Proportions shall be based on the relationship of compressive strength and W/B ratio. Mortar (grout) proportion = volume of coarse aggregate + solid portion of chemical admixture; or volume of remaining ingredients + liquid portion of chemical admixture added to quantity of water HWRA shall be of the same mass percent (%) as the total cementitious material Mix Design shall include, but not limited to, the following: Concrete mix type/class, specified strength (fc), required average strength (fcr), W/B ratio, Sand-aggregate ratio (s/a), proportion of ingredients Adjustments of Mix Proportions and Mixture Proportioning Using Test Records o Calculation of required average strength (fcr) fcr = fc + 1.34s (psi or kgf/cm2) fcr = fc 500 + 2.33s (psi) fcr = fc - 35 + 2.33s (kgf/cm2) where: fcr = required average strength (psi or kgf/cm2) fc = specified compressive strength (psi or kgf/cm2) s = standard deviation (psi or kgf/cm2)

Determination of W/B ratio The fcr obtained above shall be entered into the W/B ratio vs. strength curve to determine maximum W/B ratio. The obtained value shall be the new W/B ratio for a new concrete proportion, unless lower W/B ratio is required. Establishment of Mixture Proportions Maximum W/B ratio should not exceed maximum slump. Adjustment in volume to maintain yield shall be done by adjusting aggregate amount while retaining sand percentage of original trial mixture

o o

Same method to obtain mortar (grout) and HWRA proportions as in Fabrication of specimen Mix design shall include, but not limited to, the following: Concrete mix type/class, specified strength (fc), required average strength (fcr), W/B ratio, sand-aggregate ratio (s/a), proportion of ingredients