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IQWQ-CE1092-CPZZZ-00-0003 CIVIL WORKS CONSTRUCTION PROCEDURE 31-Oct-2016

CONTENTS

1.0 SCOPE .............................................................................................................................................. 2

2.0 REFERENCE STANDARDS AND CODES ............................................................................................ 2

3.0 EARTHWORKS ...................................................................................................................................... 2

4.0 FORMWORK .......................................................................................................................................... 4

5.0 STEEL BAR ............................................................................................................................................ 5

6.0 CONCRETE ............................................................................................................................................ 5

7.0 HDPE LINER AND GEOTEXTILE ......................................................................................................... 8

8.0 GROUT ................................................................................................................................................... 8

9.0 ROAD ...................................................................................................................................................... 9

10.0 STEEL STRUCTURLE.......................................................................................................................... 10

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1.0 SCOPE

The construction procedure is describe general procedure of civil work ,it will be applicable for all civil
work in this project (PRODUCED WATER TREATMENT PROJECT (109)).Detail method for major
civil work should refer to separate method of statement.

2.0 REFERENCE STANDARDS AND CODES

Project Specification:

IQWQ-FT-NSPDS-00-0011 Roadway and Area Paving Construction

IQWQ-FT-NSPDS-00-0018 Structural Steel Fabrication

IQWQ-FT-NSPDS-00-0019 Structural Steel Erection

IQWQ-FT-NSPDS-00-0020 Flexible Membrane Liners

IQWQ-FT-NSPDS-00-0021 Geotexitile

IQWQ-FT-NSPDS-00-040101 Concrete Design and Construction

IQWQ-FT-NSPDS-00-040801 Tank Foundation Design and Construction

IQWQ-FT-NSPDS-00-040901 Earthwork

IQWQ-FT-NSPDS-00-041002 Grout

Applicable Standards and Specifications :

ACI301 Specification for Structural Concrete

ACI315 Detail and Detailing of Concrete Reinforcement

ACI318 Building Code Requirement for Structural Concrete and Commentary

FEED drawings/Detailed Design Drawing

3.0 EARTHWORKS

3.1 General

3.1.1 Before commencement of the work CPECC shall provide COMPANY with and obtain approval for
the methods of excavation, the safety and support of neighboring private and public property, the
system of dewatering ( if applicable), the demolition of existing surface and underground structures
and obstacles, moving of any existing services, pipes, culverts and the like on the site or affecting
the works etc. ( if applicable).

3.1.2 CPECC shall install temporary lights, and other protective measures required for the safety of
personnel and the premises and maintain them in good condition.

3.1.3 The site of the work shall be cleared of all rubbish, trees, shrubs and hedges including the grubbing
out of roots indicated on the drawings, or as instructed by COMPANY.

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3.1.4 All reference points (e.g., property markers, benchmarks, etc.) shall be carefully maintained during
excavation, backfilling, compaction, and earthwork.

3.2 Excavation

3.2.1 Excavation shall be performed in accordance with the drawings to the dimensions, grades, and
elevations as noted and as required for formwork.

3.2.2 Where excavating work is carried out by machine, after excavation,the subgrade should be compact
and test as per Earthwork Specification.

3.2.3 Bottoms of all excavations shall be graded true to level and will be inspected and approved by
COMPANY before foundations or pipes are laid. CPECC shall notify COMPANY when formation
levels are reached stating the date and time that such formation is ready for inspection.

3.2.4 All loose and disturbed material shall be removed and placed in a pre-determined location approved
by Company.

3.2.5 All excavation and bearing surface shall be protected against rain and the ingress of water at all time
during foundation construction.

3.3 Filling and Backfilling

3.3.1 CPECC shall notify COMPANY of their intention to commence backfilling operation prior to starting
work on this item of the Works. All suitable excavated materials shall be used as fill. Material
unsuitable for fill, excess fills and organic debris removed by clearing, grubbing, and excavation,
shall be removed to a disposal area approved by COMPANY.

3.3.2 Fill material shall be placed in loose lifts not exceeding the following criteria, provided that the
required compaction is achieved for the full depth:

1) Structural Fill shall be placed in lifts of 200 mm (8 in) maximum in loose depth.

2) General fill shall be placed in lifts of 300 mm (12 in) maximum in loose depth.

3) Unless otherwise approved by the Company, for hand-operated compaction equipment, general and
Structural Fill materials shall be placed in lifts of 100 mm (4 in) maximum in loose depth.

3.3.3 Unless otherwise permitted in writing by the Company, backfill around or over cast-in-place concrete
shall not be permitted until the concrete has attained 75% of its specified strength.

3.3.4 To prevent unnecessary eccentric loading on a structure or foundation, every effort shall be made to
place backfill materials symmetrically and in uniform layers.

3.3.5 Backfill in pipe trenches shall not include stones or foreign materials that could damage the pipe,
until a 300 mm (1 ft) cover is obtained over the pipe.

3.3.6 The moisture content of the material being compacted shall be within ±3% of the optimum moisture
content in accordance with the applicable ASTM D1557 or ASTM D698. Fill materials shall be
conditioned as necessary to achieve the required moisture content.

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3.3.7 To prevent unnecessary eccentric loading on a structure or foundation, every effort shall be made to
place backfill materials symmetrically and in uniform layers.

3.3.8 Surface water shall be prevented from flowing into excavations by installing ditches, trenches,
protective swales, pumps, or other Company approved measures.

4.0 FORMWORK

4.1 Formwork preparation

4.1.1 Marking shall be done with ink. Outline of foundation shall be marked to facilitate installation and
alignment of formwork.

4.1.2 Formwork for concrete shall be of plywood or steel or as directed by the engineer-in-charge and shall
produce a smooth, uniform texture on the concrete surface.

4.1.3 The formwork shall be true, rigid and adequately braced both horizontally as well as diagonally. The
form shall be sufficiently strong to carry, without deformation, the dead weight of concrete, working
load, wind load and also the side pressure exerted by the green concrete.

4.1.4 Form joints shall not permit any leakage. The formwork shall be enough to withstand the effect of
vibrations practically without any deflection, bulging and distortion.

4.1.5 Top elevation of concrete shall be measured on formwork with water level.

4.1.6 Bottom of formwork shall be installed at required elevation, shall be properly leveled and prevent loss
mortar from concrete.

4.1.7 Concrete placing level shall be controlled by PVC chamfer as surveyed and marked on the shuttering.

4.2 Execution

4.2.1 Provide positive means of adjustment (such as wedges or jacks) of shores and struts. Do not make
adjustment in the formwork after concrete has reached its time of initial setting. Brace formwork
securely against lateral deflection and lateral instability.

4.2.2 Place sleeves, insets, anchors, and embedded items required for adjoining work or for support of
adjoining work before concrete placement.

4.2.3 Clean surface of formwork and embedded material of mortar, grout, and foreign materials before
concrete placed.

4.2.4 Geometrical dimension and axis position of formwork shall be correct; strength, rigidity and stability
of form shall meet requirement. When formwork is cambered, setting screeds to the same camber to
maintain specified concrete thickness.

4.2.5 Built-up steel formwork shall be used for insides and outside formwork of ring wall; and steel hoops
and vertical pipes supported by inclined support will be used for forms fixation.

4.3 Formwork dismantlement

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4.3.1 Formwork will be dismantled after the concrete has been certain strength. Fixing steel fasteners will
be dismantled first. Be careful to avoid damaging of surface and arris.

4.3.2 Formwork will be dismantled in the order as non-load bearing forms first and then load bearing
formwork.

4.3.3 Workers will stand in safety place during formwork dismantlement in case safety accident.

5.0 STEEL BAR

5.1 Acceptance of steel bar

Submit raw material quality certification documents to COMPANY prior to using.

5.2 Fabrication of steel bar

5.2.1 Fabrication of steel bar shall be achieved according to the shop drawing. Correct size and bend
angle shall be emphasized. Molded reinforced bars shall be sorted according to type, bundled with
tags, piled up orderly and avoid spoiling of mud.

5.2.2 After fabrication, steel bars shall be placed in order duly marked type, using location at site of steel
bars etc. to avoid being missed or lost.

5.3 Binding

5.3.1 Overlapping joints of steel bar shall be staggered while binding, spacing and row spacing shall meet
design requirement.

5.3.2 Overlapping of joints shall comply with requirements of governing codes, specifications and design.
The joints shall be staggered.

5.3.3 Distance between top reinforcement mesh and bottom reinforcement mesh for slab, saddle stools etc,
shall be maintained as per design requirement.

5.4 Following inspection shall be done after placement of reinforcement bars.

5.4.1 Type, diameter, amount and center to center distance of reinforcing bar shall be checked as per
construction drawings and design change list, especially the position of main reinforcing bar shall be
correct.

5.4.2 Position and overlapping length of reinforcing bar joints shall be inspected as per requirement. And
binding shall be fixed without deformation and loosening.

5.4.3 Surface of reinforcement bar shall be dust free, oil free from paint stain and granular iron dust.

5.4.4 Embedded parts shall be completed and in the correct position; records of hidden works shall be
kept prior to concreting.

6.0 CONCRETE

6.1 Requirement of material

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6.1.1 Cement: with quality certification documents.

6.1.2 Sand: local medium size or coarse sand soil content is not more than 5%.

6.1.3 Gravel: local scree, diameter 5-40mm, soil content is not more than 3%.

6.1.4 Water: clean and free from injurious amounts of oils, alkalis, salts, organic materials, or other
substances deleterious to concrete or reinforcement.

6.1.5 After cement, sand and gravel are transported to site, witness sample will be sent to a competent
laboratory to test. Then get the proper mixing ratio.

6.2 Concrete production

6.2.1 CPECC should provide the original material test include cement, sand, gravel etc., and concrete
mixing ratio report to COMPANY.

6.2.2 Most of concrete use finished product yielded in near mixing station; maybe small part of concrete
will be mixed on site by concrete truck.

6.2.3 Concrete mixing material shall be strictly mixed in according with concrete mixing ratio and
accurately weighs.

6.3 Transportation of concrete

6.3.1 Level transport will adopt tip lorry or loading machine

6.3.2 Upright transport will adopt crane with steel nacelle.

6.4 concrete pouring

6.4.1 Prior to pouring , formwork, support, rebar, pre-embedded parts shall be checked, soil, oil on rebar
and garbage, other thing of interior of formwork will be cleaned, gap will be tightly stop up, waste
inside formwork should be removed.

6.4.2 The thread of anchor bolts shall be wrapped with tape or weather stripping to prevent pour from
bonding to the bolts.

6.4.3 Concrete pouring should be carried out in accord with section and layer; each layer thickness should
accord with requirement, vibrating by vibrator.

6.4.4 Deposit concrete continuously in one layer or in layers to have fresh concrete deposited on in-place
concrete that is still plastic. Do not deposit fresh concrete on concrete that had has hardened
sufficiently to cause formation of seams or planes of weakness within the section.

6.4.5 Thoroughly work concrete around reinforcement and embedded items and into corners of forms,
eliminating air and stone pockets that may cause honeycombing, pitting, or planes of weakness.

6.4.6 Generally for foundations of routing equipment, the concrete shall be continuously poured to finish.
For other foundations, the concrete joint shall be set in the correct location.

6.4.7 Before placement of fresh concrete on the construction joint, the followed steps shall be done.

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First, roughen the surface, exposes the aggregate uniformly and does not leave laitance, loosened
particles of aggregate or damaged concrete at the surface.

Then, thoroughly clean the surface of construction joint.

Before pouring fresh concrete surface of the construction joint shall be prepared correctly and
soaking with water prior to concreting activities without free standing water.

6.4.8 Freely falling height of concrete is not more than 1.5m(accordance with the Specification), otherwise
chutes shall be used.

6.4.9 For floors intended as walking surface, trowel finish is necessary. Hand-trowel the surface smooth
and free of trowel marks. Continue hand-troweling until a ring sound is produced as the floor is
trowelled. Keep the correct slop to drainage.

6.5 Curing of concrete

After initial setting , the surface of concrete should be in moist condition not less than 7ds.

Cover with grass bag or poly membrane to preserve moisture, if available, water frequently to
maintain the proper wetness.

If white and thin dry crack appear on surface in process of curing, supply sufficient water and extend
curing time are needed.

The water storage tank set to jobsite to make sure curing.

6.6 repair of surface defects

6.6.1 Repair tie holes and surface defects immediately after formwork removal.

6.6.2 Repair the surface defects other than tie holes- outline honeycombed or otherwise defective concrete
with a 1/2 to 3/4 in deep saw cut and remove such concrete down to sound concrete. When chipping
is necessary, leave chipped edges perpendicular to the surface or slightly undercut. Dampen the
area to be patched plus another 6 in. around the patch area perimeter. Apply patching mortar and
thoroughly consolidate mortar into place. Strike off mortar, and keep the patch damp for 5 days. For
honey combs and defects repair mortar (refer attached data sheet of repair mortar and grout) shall
be used for concrete pedestals and footings. The repair mortar shall be used as per manufacturer
recommendations and safety guidelines.

6.7 Concrete testing

6.7.1 Concrete requiring a compressive strength of 20.7 Mpa (3,000 psi) or more shall be tested in
accordance with contract specification, except that samples shall be obtained as follows:

1) One sample shall be taken for of each concrete mixture on the project placed in any one day and at
least one sample for each 38 m3 (50 yd3) of concrete placed. At least one sample shall be taken for
each individual foundation that exceeds 15 m3 (20 yd3).

2) Additional samples shall be obtained if observations of tests for slump, temperature, or air content
indicate nonconformance with the Contract Documents.
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6.7.2 These cylinders are to be cured and tested at 28 days in local laboratory.

6.7.3 Concrete samples shall consist of a set of four cylinders. One cylinder shall be tested in the
laboratory after seven days and two cylinders shall be tested after 28 days. The results shall be
submitted to the Company as soon as possible. Testing of the remaining cylinder shall be performed
as directed by the Company.

6.7.4 For each concrete sample obtained, the following tests shall be conducted in accordance with
contract specification: Strength tests; Slump; Temperature; Density .

7.0 HDPE LINER AND GEOTEXTILE

7.1 The HDPE liner shall be free of holes, blisters, un-dispersed raw materials, and contamination by
foreign matter. Defect shall be repaired in accordance with the manufacturer’s recommendations.

7.2 Material batten and banding and hardware shall be match with liner.

7.3 In general, seams shall be oriented parallel to the slope. Panels of geomembrane must have a
finished overlap of a minimum of 100mm for hot wedge fusion welding and extrusion fillet welding,
but in any event, sufficient overlap shall be proved to allow peel test to be performed on the seam.

7.4 The area to be welded shall be cleaned, free of moisture. All welds shall be tightly bonded, any liner
area showing injury due to excessive scuffing, puncture, or distress from any cause shall be replaced
or repaired with an additional piece of HDPE liner.

7.5 The geotextile is putting to protect the HDPE liner inside tank foundations. So it shall have sufficient
overlap ( more than 200mm) .

7.6 test and inspection

7.6.1 The installation personnel shall at all times be on the lookout for any damaged area. Damaged area
shall be marked and repaired.

7.6.2 Onsite physical non-destructive continuous testing (peel strength test) shall be operated to ensure
watertight homogenous seams on all welds.

7.7 Compentancy and experience of the personal for installation of HDPE membrance shall be qualified by
the QA/QC team prior to start the work.

8.0 GROUT

8.1 material

8.1.1 Cementitious non-shrink grout and epoxy grout (if applicable) shall be used in this project.

8.1.2 The material shall be manufactured packaged proportioned products, and shall be stored in a dry
weatherproof area before open to use.

8.1.3 Mixing water for grout shall be clean water and free of oil, acids, alkalines, organics, and other
deleterious materials.

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8.1.4 Minimum 7-day compressive strength shall be 27.6MPa ( 4000psi).

8.1.5 Cementitious grout material (refer attached data sheet) for EMIL review and approval.

8.2 preparing

8.2.1 In the areas that will be covered by grout, the foundation shall be prepared by chipping away all
laitance (poor quality concrete) and oil-soaked or damaged concrete down to exposed fractured
coarse aggregate. Concrete chipping and removal shall not be performed with heavy tools, such as
jackhammers, as they could damage the structural integrity of the foundation. A chipping hammer
with a chisel bit shall be used for this purpose.

8.2.2 When the surface chipping is complete, the foundation shall be thoroughly swept and air-blown free
of all dust with clean, dry, oil-free air.

8.2.3 Grout forms shall be sealed to prevent grout leakage. Inside surfaces of forms shall be free of oil,
grease, and other foreign substances. Concrete surfaces to be soaked prior to placement of
cementitious grout application.

8.3 operating

8.3.1 grout shall be mixed in accordance with the grout manufacturer’s instructions.

8.3.2 All grout shall be placed in only one direction to prevent trapping air. Grouting shall be quick and
continuous to avoid segregation, bleeding, or premature initial set.

8.3.3 Grout shall be poured until the placement of grout is complete under all sections of the base, rail, or
soleplate. A single continuous pour is preferred. When multiple pours are required because of size or
base plate configuration, the Company shall approve the grout method.

8.3.4 If grout is placed through grout holes, the grout shall be placed into one hole continuously until the
grout has passed a second hole. A liquid head pressure shall be maintained at the first access hole
until a head pressure has been established at the next hole. Grout placement shall continue from the
next hole in a similar fashion.

8.3.5 If grouting around sliding surfaces, (e.g. reactor skirts, exchanger supports, etc.), grout shall be
placed in such a manner that does not inhibit movement between sliding surfaces.

8.4 curing

8.4.1 Cementitious grout surface shall be thoroughly wetted immediately after final finishing and the
grouting material is sufficiently hardened. It shall be kept wet for a minimum of five days.

8.4.2 Shims and wedges used as temporary supports for structural components and equipment shall be
removed after grout cures and the pockets filled with the same grout material.

8.4.3 Equipment shall not be placed in service before the grout has attained 80 percent of the specified 28-
day design compressive strength.

9.0 ROAD

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9.1 Work Sequence Flow:

Top soil removal.

Sub-grade layer compaction.

Laying 330 mm structural fill layer or as drawings.

Laying 200 mm sub-base layer or as drawings.

9.2 Earth Formation

Where soft spots and unsuitable materials found, it shall be removed and backfilled with approved
suitable material and compacted

9.3 structural fill layer

The stockpiled excavated soil will be used to backfill if of acceptable properties.

Keep the optimal moisture to meet the compaction ratio (describe on drawings). If the soil is too dry,
filling water and fully blending is required..

Proceed with backfilling by layers as per project specifications for structural backfilling the layer shall
be 200mm, properly compacted.

A rollers (10t) shall be used in backfill. Every layer compact 6~8times.

After compaction, test soil according to specification.

9.4 Road surface Layer

The sub base material shall be hard, durable and clean. It shall be granular material and shall be free
from organic material, clay balls, and any other deleterious substances.

The surface material should be tested as per drawings and specification.

The materials will be delivered to the site by tipper Lorries and spread and leveled by means of a back
pusher for the full width of the road. The material shall be filled and compacted to the required thickness
as specified in the drawing.

Compaction of the sub base layer shall be carried out by using vibrating roller to achieve relative dry
density as per specification

Alignment, level and surface regularity will be checked in accordance to shop drawing and Technical
Specification.

After compaction, test soil according to specification.

10.0 STEEL STRUCTURE

10.1 Structural steel shall be as shown on the drawings.

10.2 Unless shown on the drawings structural steel shall conform to the following:

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(a) Structural steel in general use shall conform to ASTM A572 Grade 50 for primary member and
ASTM A36 for secondary member.

10.3Fabrication

(a)fabrication shall be carried out in accordance with the drawings, the applicable codes listed in this
specification and the requirement and the requirements of this specification.

(b) fabrication shall commence only after shop drawings are approved by company.

(c) Platforms, stairways and handrail shall be shop-assembled in the largest units suitable for handling
and shipping

d) All burrs and sharp edges shall be removed from structural steel ,handrails and ladders.

10.4All welding shall be performed by the manual shielded arc, submerged arc,or flux cored arc welding
process.The latter process may be used provided a shielding gas is employed and the current is in the
spray transfer range.

10.5 Painting and coating

a)Structural steel members shall be painted ,galvanized or coated as shown on the drawings.

b)Painting, galvanizing and coating of structural steel shall be in accordance with the codes,standards
and specification.

c) Repair to painted or galvanized areas caused by handling, field welds etc, may be accepted if repairs
are made by method which will provide equal protection, is approved by COMPANY and the finished
piece is reinspected.

10.6 Erection

a) Unless otherwise specified or shown on the drawings ,the erection of structural steel shall conform to
the applicable codes, specifications.

b) Contractor shall furnish and install all temporary bracing as required during the erection period.

c) Contractor shall supply all pre-fabricated structures ,erection bolts ,nuts,washers load indicator
washers.

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