INSPECTION AND TEST PLAN

CONCRETE WORKS
GB513-AB01-850-PQ-PL-004

DOCUMENT DETAILS
EMPLOYER CONTRACT NO. 513-16-BD-424-00
: EPC Water Supply System from Fresh Water Wells to
PROJECT TITLE CPF Badra

EMPLOYER : Gazprom NeftBadra B.V.

CONTRACTOR : Al Bilal Group for General Contracts Co. Ltd.

CONTRACTOR JOB NO. : AB01

PROJECT DOCUMENT NO. : GB513-AB01-850-PQ-PL-004

REVISION NO. : B No. of pages (Incl. Cover Sheet) : 17

DOCUMENT DESCRIPTION : Inspection and Test Plan Concrete works

Rev. Para. Revision
Description
A ISSUE FOR REVIEW

B ISSUE FOR REVIEW

REVISION DETAILS

B ISSUED FOR APPROVAL 15/0/17

A ISSUED FOR REVIEW 16/01/17 Ali F. Samer B. Khalid H.
APPD
REV DESCRIPTION DATE PRPD CHKD
Electronic File Name : GB513-AB01-850-PQ-PL-004 _B.docx Doc Size : A4
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Hold
Para. Description of Hold
No.

LIST OF VERIFYING DOCUMENTS (ITR)

SL IE PC ITR Project ITR Number Description

NO number
1 ITR-C-0201 X GB513-AB01-850-QA-GN-0016 Concrete survey report
2 ITR-C-0202 X GB513-AB01-850-QA-GN-0017 Concrete pre-pour inspection check sheet
3 ITR-C-0203 X GB513-AB01-850-QA-GN-0018 Concrete pouring inspection check sheet
4 ITR-C-0204 X GB513-AB01-850-QA-GN-0019 Fresh concrete field test record
5 ITR-C-0205 X GB513-AB01-850-QA-GN-0020 Hot weather concreting inspection check
sheet
6 ITR-C-0207 X GB513-AB01-850-QA-GN-0021 Hardened concrete post pour inspection
check sheet
7 ITR-C-0208 X GB513-AB01-850-QA-GN-0022 Pre-cast concrete member installation
check sheet
8 ITR-C-0209 X GB513-AB01-850-QA-GN-0023 Concrete batching plant inspection check
sheet
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9 ITR-C-0210 X GB513-AB01-850-QA-GN-0024 Concrete foundation completion check list

10 GB513-AB01-850-QA-GN-007 Inspection Survey Report
DEFINITIONS AND ABBREVIATIONS
An activity that requires approval prior to proceed
A-Approval the next activity. Signature of contractor and
employer is required before proceed to next activity.
An inspection where CONTRACTOR/EMPLOYER
plans to audit, monitor or witness the activity in
RI-Random Inspection process on random or periodic basis. No formal
notification (RFI) required to inspection parties.
An activity that requires the review and acceptance
R- Review Point of the Subcontractors documentation. No formal
notification (RFI) required to inspection parties.
Monitoring or observation to verify whether or not
materials, items, or installation conform to specified
requirements. Surveillance activity may include
audit, inspection, witness of testing, review of
SV- Surveillance visit quality documentation and personnel qualification,
and evaluation of personnel performance. No
formal notification (RFI) required to inspection
parties.
An activity that requires witnessing by inspection
parties as indicated in this ITP. The Subcontractor
shall notify CONTRACTOR/EMPLOYER 24hrs in
advance. After proper notification has been
W-Witness Point provided, the CONTRACTOR is not obliged to hold
further processing if the EMPLOYER Inspector is
not available to attend or to witness the activity on
the date & time notified. Formal notification (RFI)
required to inspection parties.
An activity that requires inspection/verification and
acceptance by inspection parties as indicated in this
ITP before any further processing is permitted.
Subcontractor shall notify
CONTRACTOR/EMPLOYER 48hrs in advance. The
H-Hold Point Subcontractor shall not proceed with further
activities beyond the HOLD point unless the
responsible inspectors acceptance has been
obtained. Formal notification (RFI) required to
inspection parties.
Subcontractor, The party that contracts to
Sub contractor (SC) provide services or materials necessary for the
performance of the contract
Contractor (C) Albilal Group Co
QA/QC Quality Assurance/ Quality Control
Request for Inspection. RFI shall be submitted
RFI
24hrs in advance or as agreed with Employer.
ITR Inspection & Test Record
IM&TE Inspection, Measuring & Test Equipment
AFC Approved For Construction
N/A Not Applicable
AB01 PC Albilal Group Co Project Completion System
QCP Quality Control Procedure
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Employer (E) GAZPROM NeftBadra B.V

ITP Inspection Test Plan
TL Testing laboratory
TBA To Be Advised
NCR Non Conformance Report
CAR Corrective Action Report

REFERENCE DOCUMENTS

Document number Document description

GB513-AB01-850-QA-PL-001 Project Quality Plan

GB513-AB01-850-QA-PP-002 Corrective and Preventive Action Procedure

Method Statement of Civil Work and

GB513-AB01-850-CN-MS-028
Equipment Foundation
QCP-On site civil material testing laboratory
GB513-AB01-850-QA-PL-009
working procedure
GB513-AB01-850-QA-PP-001 Non-Conformance Control Procedure

Notes:

This document is based on widely used international codes, standards and good engineering
practices that are applied in Oil & Gas Projects and are intended to highlight the minimum tests
and inspections to ensure quality requirements are fulfilled within the scope of the document.

This document and attached/referenced ITRs are basically generated to provide guidelines to
Contractor project teams including their Sub-Contractors

This ITP serves primarily as a plan and it shall NOT be used to obtain signatures. Acceptance
Signatures shall be obtained on the referenced inspection and test records, which shall form
generic records to be handed over to the Client.

The referenced inspection and test records (ITRs) are controlled independently. Therefore, the
latest revision of these ITRs, at the time of initiation of the ITRs, shall be utilized.

When filling ITRs do not leave any blanks. If any item/activity is not applicable for the case
denote as N/A.
Use of Blanco, Tipp-ex etc on ITR is forbidden.

Civil Material Verification of test QCP-On site Testing equipments shall Testing
be in good working
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condition.

civil material testing Testing equipments shall

1 laboratory working
equipment calibration be in accordance with
testing Laboratory procedure, GB513-AB01- relevant test standard Laboratory
certificates and validity 850-QA-PL-009

Test equipments calibration

certificates shall be current.
Carry out batching plant
inspection in accordance Batching plant shall be
Batching plant inspection Site Enginee
Batch Plant with Approved by Contractor QC
2
batching plant inspection check list prior to use.
check list and approve
Civil Inspect
batching plant
for use.
Project specification for Unless otherwise Site Enginee
Verification of cement mill concrete works clause recommended, cement
3 Cement certificates for cement 7.1 used shall be of type
received at General notes for BSEN 197:Part 1 CEM III A Civil Inspecto
site concrete works or CEM III B

Cement shall be stored

Project specification for in such a manner to
Daily inspection of cement Site Enginee
Cement Storage concrete works clause avoid deterioration and
4 storage
7.1 contamination of foreign
materials. Civil Inspecto
Specification for Project Coarse and fine Site Engineer
5 Aggregate Storage Daily inspection of aggregates shall aggregates shall conform to EN
and tests Aggregate storage. concrete works 12620 EN 13043
clause 7.2 and EN 13242. Civil Inspecto

Water used for Verification of water Project Water used for concrete Site Engineer
6 concrete test specification for production shall conform
Production and curing Report. Concrete works 7.3 to BSEN 1008
Civil Inspecto
Verification of Project Admixtures shall be proved Site Engineer
7 Admixture admixture technical specification for satisfactory by trials prior to
data sheet to confirm Concrete works 7.4 use Dosage used in concrete
that proposed product Admixture technical mix shall be within the limit Civil Inspecto
is in compliance data sheet specified in technical data
sheet.
Laboratory mix design Witness laboratory mix Project specification Minimum one batch for each Site Engineer
8 Note: If supplier or the design activity in for concrete works type of mix shall be tested in Civil Inspecto
mix is of proven laboratory. clause 14.1 laboratory. Testing
record, laboratory mix Compile concrete General notes for laboratory
design testing may be laboratory mix design concrete works
waived dossier
Carry out three batches field
trial for Grade C30/37 and
C20/25.

Field trials are accepted

if average strength of three Site Enginee
Project specification for
Witness field trial activity batches exceed
concrete works clause
Field trial mix in concrete batching characteristic strength by
9 14.1 Civil Inspect
plant 6 mPa if the batching
plant.is computerized and Testing
General notes for laboratory
able to produce
concrete works.
Concrete with standard
deviation less than 3.5.
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For all other types of

batching plant, field trial
acceptance criteria shall
be agreed between the
parties prior to start of field
trials.
Project specification for Rebar used shall conform to
10 Reinforcement Review of rebar mill concrete works clause 7.6 BSEN 1992 and shall be Site Enginee
certificates General notes for with yield strength 500mPa.
concrete works. Civil Inspecto

Inspection of Reinforcement shall be

reinforcement stored above ground on Site Enginee
Storage of Storage area. Project specification for racks and shall Always be
11 reinforcement concrete works clause 7.6 covered.
Civil Inspecto
Inspection findings to be Reinforcement shall be
documented in general stored in separate lots by
inspection record. size

Before placing rebar,

internal surfaces of form
work shall be clean &
Surveillance inspection release agent shall be
of surface of form work Project specification for applied to the faces of form
that faces concrete works clause 7.9 work to prevent adherence
Concrete surface. of concrete.

Assembly of Surveillance inspection Temporary openings shall

12 Formwork of form Work design and be provided to remove Site Enginee
supports. Relevant IFC drawing. rubbish. prior to concreting
Form work shall be
Surveillance inspection constructed such as to
of form Work dimension permit easy removal
in plan for compliance Form work shall be tight
against IFC drawing. enough to prevent grout loss Civil Inspecto
and secured so as to be
strong enough to withstand
Self-weight, lateral pressure
and stresses from
placement and vibration of
concrete.

Permanently exposed edges

of concrete member shall
have 25 mm chamfer.

Surveillance inspection Project specification Reinforcement shall be

of rebar Size, numbers for concrete works free of loose scale or rust, Site Engineer
and shape of bend clause 7.6 grease, oil paint or any other
13 Installation of during installation. deleterious
reinforcement
Inspection of cover to Relevant IFC Matter prior to placement.
rebar and for drawing.
cleanliness during final Binding wire shall be of size
Civil Inspector
inspection prior to 1.2mm and ends of binding
concreting wire shall be tucked inwards.
Anchor bolts and embeds shall
comply with requirements of
Verification of anchor relevant IFC and Standard
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bolt/embeds test Project specification drawing for anchor bolts. Site Engineer
certificates. for concrete works Embedded items shall be
clause 7.7 securely fixed, if required
Anchor Inspection of anchor templates or other supports
Bolts/Embedded bolts and embeds Relevant IFC drawing shall be provided. Civil Inspector
14
Items installation installation for position
in plan and levation. Embedded items shall be
Inspection of provision clean and free from rust,oil,
of grout pocket. grease or any foreign Material.
Exposed thread of anchor
bolts shall be protected from
damage during and after
concreting by wrapping using
protective tape or by applying
grease.

Pre-cast elements shall be

stored in such a manner which
eliminates the possibility of
damage.

Precast elements shall be

marked with cast date and
foundation identification.
B
Before lifting from casting
beds, pre-cast elements will
have achieved sufficient
Inspection of form strength (70% of required Site Engineer
work and rebar characteristic strength) to
installed. Relevant IFC drawing prevent any damage to
Inspection of bedding concrete.
Pre-cast elements surface prior to Civil Inspector
15 casting and installation. Initially, trials shall be
installation conducted by placing concrete
Review of survey samples adjacent to pre-cast
report prior to member and curing them
installation. similar to curing pre-cast
members and testing them at
3 or more days to determine
number of days required to
Reach 70% characteristic
strength.

Position of member in plan

and elevation shall be in
accordance with IFC drawing
Joint inspection with (Check survey report). Site Engineer
16 Pre-pour Inspection of construction and Installation of form work, rebar
structural members Employer Relevant IFC drawing and embed items shall be in
representatives. accordance with latest revision
of IFC Drawing. Civil Inspector
Form work shall be clean and
free of rubbish.
Contraction joints, expansion
joints shall be in accordance
with the drawings.
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Inspection of moisture Approved concrete Correction for Moisture content

content in aggregates mix design Project in aggregate shall be Site Engineer
at batching plant. specification for calculated prior to mixing of Civil Inspector
Verification of mix concrete works concrete.
17 Concrete production design used at the clause 9.1 During hot weather truck Testing
and transportation batching plant mixers drum shall be insulated laboratory
Inspection of fresh Every truck load delivered to
concrete slump and site shall have a delivery
temperature for first Ticket .
load in the morning
and in the afternoon.

Slump test shall be carried out

for each truck supplied.
Concrete temperature shall not
exceed 35oC.

Details of each truck arrived at Site Engineer

site shall be recorded in pour Civil Inspector
card. cubes shall be cast as
Approved concrete per concrete specification Testing
Inspection of fresh mix design. requirements. Minimum 2 laboratory
Fresh Concrete concrete delivered to specimens shall be cast for
18 sampling and testing site prior to pouring Project specification each age.
for concrete works
clause 14.2 Strength of concrete sample at
any age is the average of
minimum 2 specimens tested
at that age.

Test specimen cast shall be

protected from sun, wind and
contamination and transported
to curing tank early next
morning for curing.

Concrete shall be placed in

horizontal layers not
exceeding 400mm.
Concrete shall be vibrated to Site Engineer
the full depth of layer without Civil Inspector
19 Inspection of concrete Project specification causing segregation.
Concrete placement placement and for concrete works Vibration of rebar or formwork
and vibration vibration clause 9.1.2 during concrete vibration is not
permitted
Vibrator shall be inserted and
withdrawn so that proper
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consolidation takes place and

segregation does not occur

Aggregate storage shall be

covered Ice and / or chilled
Inspection of hot Project specification water shall be used for Site Engineer
weather concreting for concrete works concrete production
20 Hot weather measures in batching clause 9.2.2 Concreting shall be done Civil Inspector
concreting plant and at pouring during early hours or late night
site ACI 305 R Concreting shall start only
during ambient temperature
decreasing period.
Concreting shall not be carried
out at ambient temperature
+35oC and rising.

Immediately after finishing

concrete, top surface shall be
Inspection of concrete covered with polyethylene
finishing Project specification sheet ensuring sufficient Site Engineer
for concrete works overlap.
21 Finished Concrete Inspection of After final set, wet hessian Civil Inspector
surface protection and protection of concrete shall be placed over the
curing surface soon after concrete surface and kept
finishing and after continuously wet by pouring
setting the next day water underneath polyethylene
early morning sheet for 7 days.
On vertical surfaces, after
striking form work, concrete
surface shall be wrapped with
wet Hessian and covered with
polyethylene sheet.Hessian
shall be kept wet continuously
for minimum 7 days.
Post pour inspection shall be
jointly carried out with client.
Inspect the concrete Site Engineer
22 Hardened concrete finished surface and Concrete repair Defects if any shall be
post pour inspection document any defect procedure documented in the relevant Civil Inspector
ITR.
Repair of defects if any shall
be in accordance with
approved repair procedure.

Curing tank water temperature

shall be as per relevant
standard. 18-220C is preferred Site Engineer
range.
Sample set shall have a Civil Inspector
Hardened test Concrete test register specific identification number
specimens Check specimen like 1,2,3 etc., and each Testing
23 transportation to identification numbers specimen in a set will have laboratory
laboratory and curing entered. identification like A,B,C etc.,
For example, if any 4
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specimens are made in a set #

1, the samples must be
identified as 1A, 1B, 1C and
ID.
Strength test shall be in
accordance with BSEN
standard or to local standard.

Acceptance criteria for Site Engineer

Project specification strength test and actions in
Hardened Concrete Witness of hardened for concrete works case of non-compliance shall Civil Inspector
24 Strength test concrete strength test clause 7.5 and 14.2 be in accordance with
Specification for concrete Testing
works. laboratory

All inspection relevant check Site Engineer

sheets and test reports for
Foundation each sub system shall be Civil Inspector
25 completion and Compile civil Civil QC records compiled, signed off and
handover to next completion dossier for during construction foundation. Testing
construction relevant sub- system Handed over to next laboratory
discipline construction discipline.