SAES-Q-012 (Criteria for the Design and Construction of Pre-cast and Pre-stressed Concrete

Structures)

4. Design

•The design shall be in accordance with the following:

1. ACI 318/318M
2. PCI Design Handbook (PCI-MNL-120) and (PCI-MNL-122)

•Pre-cast concrete work shall be designed to carry all dead and superimpose loads, including hanging
loads, lateral loads, and loads arising from storage, handling, and transportation

•Compressive Strength - Normal & Light Weight Concrete, 28 days compressive strength at 35MPa
(5,000 psi)

•Grout shall be non-shrink, non-metallic, pre-mixed grout

•Grout for Hollow Core Slab, shall be sand-cement grout or concrete, 14 MPa (2,000 psi)
compressive strength

•Water Cement Ratio shall not exceed 0.40

•Concrete cover for pre-cast and pre-stressed concrete shall as per ACI 318

•Anchor bolts, metal inserts and projecting steel items shall be hot dip galvanized.

•Tolerance for inserts and construction shall be in accordance with PCI MNL-135.

•Design and Construction of precast wall panels shall be in accordance with ACI 533R and
PCI-MNL-120

5. Materials

•Cement - Minimum cement content for pre-cast concrete shall be 370 kg/m³ of concrete

•Aggregates - shall be as per 09-SAMMS-088

•Water - shall be as 09-SAMSS-097

•Admixtures - shall be as 09-SAMSS-097

•Non-shrink Grout - shall be as per SAES-Q-010

•Sand-Cement Grout - Portland cement, and clean, natural sand; mix at ratio of 1 part cement to 2-½
to 3 parts sand, by volume, with minimum water required for placement.

•Reinforcing Bars - ASTM A615/A615M Grade 60 (422 MPa),

- ductile steel elements ASTM A706/A706M Grade 60 (422 MPa)
- Coated Reinforcement shall be Fusion Bonded Epoxy (FBE)
6. Fabrication

•Fabrication of pre-cast and pre-stressed concrete members shall be in a Saudi Aramco approved
plant. Approval shall be in accordance with SAEP-383.

•All pre-cast and pre-stressed concrete members shall be fabricated in accordance with follwing:

1. Pre-stressed Concrete Institute

2. Manual for Quality Control for Plants and Production of Pre-cast Pre-stressed Concrete
Products (PCI-MNL-116)

•All architectural pre-cast concrete members shall be fabricated in accordance with the following:

1. Pre-stressed Concrete Institute

2. Manual for Quality Control for Plants and Production of Architectural Pre-cast Pre-stressed
Concrete Products (PCI-MNL-117)

•All concrete surfaces in direct contact with earth shall be coated with two coats of coal tar or bitumen
coating that conforms to APCS-3 or APCS-10 in accordance to SAES-H-001.

•All precast members where the reinforcement protrudes through the surface or where shadow lines
are caused by reinforcement too near the surface shall be rejected.

•25mm chamfers shall be provided at exposed edges of pre-cast/pre-stressed units.

•Steam curing can be used for pre-cast concrete.

•Location of openings for ducts, exhaust fans, cable trays, piping, etc., shall be inspected, checked,
and verified against design drawings during fabrication of all pre-cast and pre-stressed concrete
members

7. Delivery, Storage and Handling of Material

•Pre-stressed concrete members shall be lifted and supported only at the lifting and support
points shown on the shop drawings during handling, storing, and transporting.

•Proper equipment and methods of bracing shall be used during transporting to ensure the members
arrive at the jobsite undamaged.

•Members shall be kept free of mud and other damaging materials at all times.

•Lift and support units at the designate lifting and support points only.

8. Erection

•Erection of precast concrete shall be in accordance with the following:

1. PCI MNL-127 Erector's Manual: Standards and Guidelines for the Erection of Precast
Concrete Products.
2. PCI MNL-132 Erection Safety Manual for Pre-cast and Pre-stressed Concrete.

•Installation of pre-c ast foundations shall comply with SAES-Q-005 Section 4.4.3.
 •All pre-cast members shall be installed in proper sequence and adequate temporary supports shall be
provided to control alignment, deflection, and stress levels.

•Pre-cast Members shall be grouted.

•Pre-cast units shall be lifted only from the lifting points shown on the shop drawings.

•Field cutting or drilling holes of pre-cast units is not allowed unless reviewed and supported by
structural calculations.

•If supported with structural calculations, field cutting in solid wall panels shall be limited to 250 mm
(10-inch) round opening.

9. Inspection and Testing

Inspection and Testing shall be in accordance with Section 5 of SAES-Q-001.

Pre-cast units may be rejected for any of the following:

•Defects as listed in PCI MNL-116, as applicable

• Surfaces with finish deficiencies
• Damage during lifting, transporting, and construction operations
• Dimensional variations exceeding the required tolerances