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CONVEYOR SYSTEM FOR UNLOADING FACILITIES TERMINAL MULTI PURPOSE TELUK LAMONG PT.

PELABUHAN INDONESIA III ( PERSERO )

OWNER CONTRACTOR PROJECT TITLE LOCATION PROJECT NO.

: PT. PELINDO III ( PERSERO ) :PT. ULAN BUANA ENGINEERING :CONVEYOR FOR UNLOADING FACILITIES :EAST JAVA, INDONESIA :-

MULTI PURPOSE CONVEYOR SYSTEM JETTY TELUK LAMONG


DOC. NO. : PIII-UBE-002.PR.062014

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APPENDIX 8-2 SPECIFICATION FOR CIVIL/STRUCTURE


8-2.1 8-2.1.1 CIVILS AND STRUCTURAL SPECIFICATION DESIGN All Civil and structural designs shall be based on the Codes, Specifications and Standards referred to herein. CONTRACTORs designs may use other Codes, Specifications and Standards which it has found from experience to be appropriate providing these are not less stringent than those referred to herein. CONTRACTORs design shall be based on the following Codes, Specifications and Standards, latest editions. -

SSPC - Steel Structures Painting Council ASTM - American Society of Testing Materials AISC - American Institute of Steel Construction ACI - American Concrete Institute UBC - Uniform Building Code ANSI - American National Standard Institute SII - Standard Industry Indonesia SNI - Standard Nasional Indonesia ASCE - American Society of Civil Engineers JIS - Japanese Industrial Standard

8-2.2.2

FOUNDATIONS Foundation for the structure and building will follow the recommendation as per the final soil report.

Foundations shall be designed for total and differential settlements not to exceed 25 mm and 15 mm respectively.

This design parameter shall be applicable to structures sensitive to total and differential settlements shall be reviewed on a case by case basis, and subject to OWNER approval.

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8-2.2.3

PILING CONSTRUCTION DRAWINGS (1) Specifications and Piling Construction Drawings showing the locations of the piles referenced to the existing OWNER Coordinate System. Piles shall be identified in sequence either by a number or letter/number designation. Duplication of identifying numbers will not be acceptable. CONTRACTOR shall provide OWNER with 4 (four) copies of all pile load tests (static test), 4 (four) copies of PDA test and 3 (three) copies of complete pile driving records.

Additionally, CONTRACTOR shall, upon completion of piling, provide OWNER with 5 (five) copies of the complete pile record in the tabular form to be proposed by OWNER.

Detailed design calculations for each piled foundation which shall clearly show design assumptions and/or design parameters, loads/forces and references to the Section of the Code/Standard on which the designs are based.

(2)

CONTRACTOR shall prepare and periodically up-grade as design progresses the following data for each facility and/or unit as a check by OWNER on piling requirements.

Pile types Pile capacities Estimated length for each type of pile Number of piles for each type Estimated total linear meters of each type of pile Pile design criteria for pilling work

(3)

CONTRACTOR in its Lump Sum shall provide for the supply, delivery and installation of all piles including, but not limited to, supervision, inspection, layout, blast cleaning/coating and pile driving records

(4)

CONTRACTOR in its Lump Sum shall carry out static pile loading test (2 point for each tension, lateral test and compression test) to ensure pile design criteria before piling work done. Dynamic pile loading test (PDA Test) shall carry out on 4 (four) piles at beginning of piling work. PDA test also shall be applied after completion of

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piling work on driven pile that indicated has under specification. Pile capacity at least on 2 (two) points driven pile.

(5)

Pile equivalency will be in accordance to OWNER and CONTRACTOR clarification staled elsewhere.

In connection with the above:

All design and calculation shall be submitted to OWNER for approval prior to further stage. Only approved design shall be used for construction.

8-2.2.4

STRUCTURAL STEEL (1) Structural steel materials shall conform to ASTM-A36, JIS G 31011 SS 41 or equivalent with minimum yield strength of 36,000 psi, and designed in accordance with AISC and UBC.

(2)

CONTRACTOR shall prepare and periodically upgrade as design progresses the tonnage of structural steel, as a check by OWNER, for the following: a) Transfer Tower b) Bent c) Gallery Conveyor d) Railway for Portal Scraper e) Transformer yard f) Offsite facilities (if any) g) Miscellaneous structures h) Others

8-2.2.5

CONCRETE, CONCRETE FOUNDATIONS AND CONCRETE STRUCTURES (1) Concrete Concrete for general purpose work include pavement shall conform to ACI318 and UBC and have an average compressive strength of 3000 psi at 28 days.

Concrete for foundation, road and structure shall have an average compressive strenght of 4000 psi at 28 days.

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Concrete for pre-stressed concrete shall have an average compressive strength of 7250 psi at 28 days.

Cement shall conform to ASTM C-150 and be type I for all on land concrete structure.

Reinforcement bars for concrete shall conform to SNI 07-2052 2002 equivalent to JIS G3112; BJTD 40, minimum yield strength is 4000 kg/cm2, and for plain bar BJTP 24, minimum yield strength is 2400 kg/cm2.

Pre-stressing tendons for pre-stressed concrete shall conform to ASTM A-421, ASTM A-416 or ASTM A-722 and have the minimum tensile and yield strengths stipulated in referenced ASTM specifications. (Fc = 7250 Psi)

Steel wire fabric reinforcement shall conform to ASTM A- 185.

Sand and aggregate shall conform to ASTM C-33.

(2)

Concrete Foundations and Concrete Structures Specifications, Material Quantities, and Concrete Foundation. Construction Drawings for shallow spread footings and raft type foundations (where applicable) for equipment, structures and buildings supported at grade. Also similar documents for the foundations supported on piles.

Specifications, Material Quantities and Construction Design Drawings for all Reinforced Concrete Structures, above and below grade, consisting of Plans. Elevations, Sections and Details.

Specifications, Material Quantities and Design/Construction Drawings for reinforced concrete structures for all equipment and items of supply of a special nature such as compressor, clarifier, settling pond, if any.

Specifications and Design/Construction Drawings shall, in addition to the Project Design Parameters, include the specific design requirements.

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Concrete Foundation and Concrete Structure Construction Drawings referred to above, including Reinforcement Bar Bending Schedules, shall be clear and complete and show all pertinent requirements and information such as, but not limited to, dimensioned locations, elevations and dimensions of members, size/spacing/location of reinforcement, size/location/projection of anchor bolts, details of concrete inserts, pockets, and types of surface treatment/finish to permit rapid and easy construction.

Detailed design calculations for each concrete foundation and each reinforced concrete structure which shall clearly show design assumptions and/or design parameters, loads/forces and references to Section of the Code/Standard on which the designs are based. All calculation shall be use LRFD methode.

As above for all other civil engineering work including paving and temporary facilities.

In connection with the above:

All design and calculation shall be submitted to OWNER for approval prior to further stage. Only approved design shall be used for construction.

(3)

CONTRACTOR shall prepare and periodically upgrade as design progresses the cubic meters of concrete, as a check by OWNER, for the following: a) Foundations for Structures & Buildings. b) Concrete upper structures for building. c) Paved Areas. d) Roads and ditch. e) Miscellaneous Concrete. f) Temporary Facilities.

8-2.2.7

CONCRETE BUILDINGS (1.) Detailed Requirements Substation & Control Room Building Substation buildings shall be concrete block construction with roof, floors and columns of concrete and walls of concrete block.

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Roofing shall be polypropylene or approved equal type roofing finished with local gravel. Insulation shall be 50 mm thick Fesco board or other approved equal incombustible material having a non-capillary structure and resistant to fungus growth.

Ventilation/Windows shall be aluminum projected and/or fixed sash. Ventilation shall be completed with exhaust fan.

Each building shall be air conditioned as required.

Exposed surfaces of sash shall have a clear anodized finish of 0.02 mm minimum thickness.

External door for substation building shall be steel doors (manufactured standard).

Control room shall use raised floor for sufficient cabling.

8-2.2.8

STEEL STRUCTURES Steel structure work (except steel building & transformer yard) consists of: Transfer tower (TT-01, TT-2, TT-03, TT-04).

Conveyor gallery BC-01, BC-02, BC-03, BC-04.

BENT or Gallery Support (if any).

Structures such as Transfer Tower and gallery conveyor shall be structural steel. The first and the end columns on each gallery segment shall be linear with the gallery support.

Specifications and Design Drawings for Structural Steel Structures consisting of Plans, Elevations, Sections and Details which define completely the Structure(s) requirements including, but not limited to. dimension elevations, member sizes/weights, location of fixed/removable handrail, stairs, ladders, equipment framing/floor cut-outs, type(s) of flooring, hoist/crane, equipment support connection, member forces/reactions/moments and column anchor bolts to permit a structural steel fabricator to design, detail and prepare shop drawings, supply and fabricate the structural steel structures.

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Dead, live, wind, earthquake, thermal and operating loads for supported equipment shall be listed on the design drawings or in appropriate calculations. CONTRACTOR shall assume that for special equipment such as conveyors required in material handling systems, the conveyor galleries and related structural steel will form part of the CONTRACTORs design, and supply the structural steel necessary to support the special equipment on the Structural Steel Structure.

Detailed design calculations for each structure which clearly show design assumptions and/or design parameters, loads/forces and references to Section of the Code/Standard on which the designs are based. Check Vendors calculations for shop details and shop erection/detail drawings to ensure correct interpretation of design Drawings. Specifications and Schedule for each structure. This shall not relieve the Vendor from complying with its responsibilities to perform in accordance with the terms of its CONTRACT.

CONTRACTOR shall done review or recalculation existing structure (such as existing 2852-H, conveyor gallery 2805-V, 2D Building) that will support new facilities such as new conveyor or new gallery. BENT shall be constructed from Transfer Tower for supporting new gallery. Gallery 2805-V Modification shall be built with new steel structure, during dismantling and cutting work

CONTRACTOR shall take account for not make any damage to existing conveyor gallery steel structure. CONTRACTOR shall substitute roofing, siding and checkered plate. -

CONTRACTOR shall calculate and assume that for transfer tower (TT-6805-H and TT-6806-H) will support new conveyor (from others project), this transfer towers shall have sufficient strength and stability.

In connection with the above: All design and calculation shall be submitted to OWNER for approval prior to further stage. Only approved design shall be used for construction.

8-2.2.9

MISCELLANEOUS STRUCTURAL STEEL PLATFORMS/ ATTACHMENTS

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Specifications and Designs for all Miscellaneous Structural Steel Platforms/Attachments supported on or connected to gallery and junction tower.

The Design Drawings shall consist of Plans, Elevations, Sections and Details which define completely the Platforms/Attachments including, but not limited to, dimensions, loads/forces, member sizes/weights, handrails, ladders, stairs, type of flooring, brackets, davits, hoists, etc. to permit a structural steel fabricator to design, and prepare shop drawings, supply and fabricate the steel requirements for the Platforms/Attachments.

Detailed

design

calculations

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used

for

each

Platform/Attachment which shall clearly show design assumptions and/ or design parameters, loads/forces and references to Section of the Code/Standard on which the designs are based. Check Vendors calculation for shop details and shop erection/detail drawings to ensure correct interpretation of Design Drawings, Specifications and Schedule for each Platform/Attachment. This shall not relieve the Vendor from complying with its responsibilities to perform in accordance with the terms of its CONTRACT.

Specific Requirements Flooring for Platforms, Operating Floors and General Floor Areas a) All flooring for Platforms, Operating Floors, General Floor Areas, Drainage ditches, etc. shall be standard type open grating. The lowest platform of transfer tower shall be checkered plate with minimum thickness 6 mm (galvanized). Minimum width for each stairs are 750 mm. b) Grating for ditches shall be heavy duty open grating type. c) Bar thickness and depth shall be suitable for its intended service and loads with acceptable deflections. d) Grating shall be supplied hot dip galvanized. The dimension are 32 x 5 mm (serrated). e) Checkered Plate shall be galvanized with minimum 6 mm thickness. Walkway for conveyor shall be checkered plate. Under belt conveyor shall be equipped with corrugated alumunium 1.02 mm thickness. f) Stair treads shall be standard type open grating with non-slip nosing and galvanized. All steel work shall be adequately protected by a suitable paint system to resist corrosion from the corrosive marine atmosphere.

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Siding for Buildings Siding for all buildings shall be extended to a practical level above the operating floor(s) to provide good protection to the operating floor and operators against heavy driving rains.

Siding shall extend from 2.0 m above floor level to the eaves.

The lower 0.5 m above Plant level shall be made of bricks.

8-2.2.10

ROADS AND DRAINAGE Roads throughout the Storage area shall be of reinforced concrete construction.

Roads shall be designed as a minimum for HS-20-44 truck or 80 tons HC 218 J truck mounted crane.

Main and Secondary Plant paved roads shall be standardized and consistent with the existing roads on OWNERs Plant

Drainage shall be designed for based climatic condition in Teluk Lamong site area for rain fall.

CONTRACTOR shall carry out CBR tests along the proposed roads to assure that the design and construction to be adopted, such as slab thickness and sub-grade preparation, will meet the loading requirements.

8-2.3

DESIGN LOADS Design for Wind Loads shall be in accordance with ASCE. Basic design wind velocity shall be 120 km/hr (33.3 m/s).

For the Process Structure and all other structure buildings the design shall be in UBC and for seismic zone refer to Indonesian code (SNI). Peak ground acceleration is 1.42 cm/sec2 on a 20 years return period with the dominant period of shear waves less than 0.6 sec.

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A Seismic Risk Analysis Report has been prepared to CONTRACTOR for reference. This report indicates the probability that an earthquake of 6.6 magnitude on the Richter Scale with intensities exceeding VI on the Modified Mercalli Scale could be experienced at the Teluk Lamong Site once in 20 years.

Minimum design Live Loads for buildings, floors and process structures shall be as follows: a) Flat Roof Area b) Access Platforms. Walkways and Stairs c) Operating and Maintenance Floors d) Warehouse Floors = 100 kg/m2 = 500 kg/m2 = 625 kg/m2 = 1,25 kg/m2

Specific design requirements for buildings and structures shall be in accordance with UBC and ASCE.

8-2.4

SOIL INFORMATION Preliminary Soil Investigations for the Site area have been completed.

These Soil Investigation Report prepared by PT. SOILENS is available to CONTRACTOR for reference only, not for final design of the foundations.

CONTRACTOR shall carry out the additional soil investigation to ensure the latest information about the general soil characteristic data at the site. Information concerning this report can be obtained from OWNERs.

8-2.5

CLIMATIC CONDITION Climatic conditions for the Teluk Lamong Site area are contained in Section 7.