Construction Spec For Concrete Work

Doc. No. 900-SPE-RC0-1001 Rev.
6B
TANGGUH LNG Project TLNG Author’s Org. KJP
BPMIGAS KJP Doc. No. S-900-3120-001 Date 06 Feb, 06
BP Berau Ltd. KJP Job Code J-3400-20-0000 Sheet 1 of 18
Construction Specification for Concrete Work
Table of Contents
1. GENERAL...................................................................................................................................2
2. INGREDIENT OF CONCRETE...............................................................................................2
3. CONCRETE MIXING ...............................................................................................................4
4. REINFORCEMENT ..................................................................................................................6
5. CONCRETING...........................................................................................................................7
6. REPAIR OF SURFACE DEFECTS .......................................................................................12
7. PROTECTION OF UNDERGROUND CONCRETE...........................................................12
8. PRECAST CONCRETE ..........................................................................................................13
9. HOT WEATHER CONCRETE ..............................................................................................14
10. MASS CONCRETE..................................................................................................................15
11. INSPECTION AND TEST.......................................................................................................15
Attachment – 1 : Technical Information of Coating Material for Underfround Concrete

Surface (6 pages)
X Core Non-core Lifecycle Code B
For Information For Review For Approval X For Release For As-Built
Rev. Date Page Description Prep’d Chk’d App’d BP App’d

1A 26 Mar. 4 All Issue for Approval. Y. Kikuta R. Saito R. Saito
5A 01 Sep.05 All Issued for Approval. Y. Kikuta N. Okajima N. Okajima
6A 31 Oct. 05 2, 4, 6, 10 Issued for Release. Y. Kikuta N. Okajima N. Okajima
6B 06 Feb. 06 As marked Revised as marked (Surface Coating, Pit Leak Test, etc.) Y.Kikuta N. Okajima N. Okajima
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BP Berau Ltd. Tangguh LNG Project Doc. No. 900-SPE-RC0-1001
KJP Doc. No. S-900-3120-001 Rev. 6A
Construction Specification for Concrete Work Sheet No. 2 of 18
1. GENERAL
1.1 Scope
The specification covers the construction requirement of the Onshore Concrete Works for TANGGUH LNG
PROJECT for BP Berau, Ltd.
1.2 References
1.2.1 Codes and Standards
ACI “American Concrete Institute”
ASTM related to orks described hereinafter.
1.2.2 Project Specifications

S-900-3112-001 “Construction Specification for Earth Work”
S-900-1520-105 “Inspection and Test Plan for Concrete Work”
S-900-1310-301, Surface Coating Extent for Underground Foundations
1.3 Conflict in Requirement

Conflict between requirements set forth in the technical documents, shall be notify to KJP for resolution.
Note, however, that in the event of conflicts, precedence of documents decreases as follows: -
1. Each design drawings
2. Standard drawings and specifications
3. International codes and standards as ACI, UBC, ASTM etc.
2. INGREDIENT OF CONCRETE
2.1 Cement
2.1.1 Material Description
Portland Cement Type I and V of ASTM C150 shall be used. Type V is especially for underground parts of
reinforced concrete objects. Alternatively the following type as per ASTM C595 may be used with Owner
and KJP’s approval: -
• Portland Blast Furnace Slag Cement
• Portland-Pozzolan Cement
• Slag Cement
Manufacturer’s Test Certificate shall be submitted to KJP on each delivery.
2.1.2 Storage
Cement shall be stored in sheds, bins or silos which will provide protection from moisture and contamination.
Cement bags shall be stored minimum 0.3m above floor, that floor shall be concrete paved.
Consignment of cement shall be stored as received and shall be consumed in the order of delivery.
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2.1.3 Rejection of Cement Material

Cement remaining bulk storage for more than 6 months or cement in bags in local storage in the custody of a
vendor for more than 3 months after completion of tests shall not be used. Cement that has become caked or
partially set also shall not be used.
2.2 Aggregates
Both Fine and Coarse Aggregate shall meet the requirement of ASTM C33. Fine Aggregate shall consist of
clean, washed, natural or crushed sand of uniform gradation. Coarse Aggregate shall consist of washed
gravel or washed crushed stone, having hard, strong, durable piece, free from adherent coating, or other
weak, deleterious substances.
Maximum size of coarse aggregate is 20mm.
The source of material shall not be changed without KJP’s approval.
2.2.2 Storage
Aggregate stockpiles shall be arranged and used in a manner to avoid excessive segregation and to prevent
contamination with other materials or with' other sizes of like aggregates. To ensure that this condition is
met, any test for determining conformance to requirements for cleanness and grading shall be performed on
samples secured from the aggregates at the point of batching. Stockpiles of sand shall be allowed to drain to
ensure relatively uniform moisture content throughout the stockpile.
2.3 Mixing Water

Mixing water for concrete shall be meet requirements of ASTM C 94 and free from injurious amounts of oil,
acid, salt, alkali, organic matter, and other deleterious substances. Seawater shall not be used for mixing
concrete.
Water shall have a pH between 5.0 and 8.5.
2.4 Admixture
Admixtures shall conform to the requirements given in ACI 212.3R, 212.4R, ASTM C 260, ASTM C 494
ASTM C 618 or ASTM C 1017 and shall not contain chloride nor any corrosive agents.
2.4.2 Storage
Admixtures shall be stored in a manner that will avoid contamination, evaporation, or damage, conforming to
the recommendations and instructions given by the manufacturer.
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2.4.3 Usage
Careful attention should be given to the manufacturer’s instruction.
When more than one admixture are used, the combination of such admixtures shall not harmful effects on the
concrete. Subcontractor shall submit written statement to prove no harmful effects prior to use.
3. CONCRETE MIXING
3.1 Production by Batch Plant

3.1.1 General Requirement
This plant shall have functions capable for continuous concrete supply and for testing requested in the
specifications during construction work. The plant shall be located within the plant fence. This batch plant is
installed as a temporary facility, thus, all facility shall be removed and cleared after the construction work is
completed.
The batch plant and associated facilities shall include, but not limited to,:
• Batching and mixing units
• Aggregate bins/weighing hopper
• Cement weighing hopper
• Cement silos
• Operator cabin
• Conveyors
• Water chilling system
• Insulated water storage tanks and water pump.
• Cement & admixture storage warehouse
• Aggregate storage bins/shelters/yard
• Laboratory and office with toilet
• Curing pool for compression test cylinder
• Washing basin for truck mixers
• Drainage facilities including siltation pits.
• Generator with electrical distribution system
• Mixer trucks
• Lighting system
Subcontractor shall submit his complete plan to meet the requirement herein and hereunder for KJP’s
approval before commencing related works.
3.1.2 Facility Requirement

(1) The batch plant shall be a full-automated wet mixing type, and be designed to have capacity to produce
the appropriate and sufficient quantity of concrete. The capacity of batch plant shall fulfill maximum
construction requirement. At least two batch plants or mixers shall be installed for a backbuck-up
purpose.
(2) The batch plant should be painted white to reflect the sun and be directly shaded from the sun.
(3) Aggregate storage bins shall have partitions to separate fine and coarse aggregate, and different size/type
of aggregate. The floor of the bins shall be concrete to prevent contamination with soils. The storage bins
_ __ shall have roofs for sunshade and equipped with water spray system.
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(4) The cement silos shall be an adequate size to store sufficient cement to ensure continuity of work. The
silos shall be equipped with thermometers to check temperature of cement. The silo shall be separated
each cement type. Ventilation system shall be provided for cement storage.
(5) The laboratory shall have equipment for the field testing of concrete and concrete materials.
(6) Temporary drainage system including siltation pits shall be provided and drains from the batch plant
area shall be treated prior to discharge to the surface water drainage system.
3.1.3 Measuring and Batching

(1) Concrete Production
The weighing and mixing shall be a full automated.
Quality of concrete produced in the plant shall meet the standard stipulated in "Specification for Plain
and Reinforced Concrete" 99-SPE-1631. The standard includes:
- Material for concrete: cements, admixtures, mixing water, aggregates.
- Proportioning: concrete strength, durability, slump, maximum size of coarse aggregate, and
determination of standard deviation.
- Production of concrete: temperature control of concrete materials including mixing water and
weather conditions.
(2) Accuracy of Scales

The accuracy of weighing scales shall be within ± 0.4 percent of their total capacities. Standard test
weights shall be kept available on site for checking the accuracy of all scales.
(3) Accuracy of Batching

Batching equipment shall be operated within the tolerances given in ACI 304 R.
(4) Mixing
The concrete shall be mixed in a batch mixer capable of thoroughly combining the aggregates, cement,
and water into a uniform mass within the specified mixing time, and of discharging the concrete
without harmful segregation.
(5) Control of Admixtures

Separate containers and measuring devices shall be used for admixtures. Admixtures shall be charged
into the mixer as solutions. The liquid shall be considered a part of the mixing water. Admixtures that
cannot be added in solution may be weighed or may be measured by volume if so recommended by the
manufacturer. If two or more admixtures are used in the concrete, they shall be added separately to
avoid possible interaction that might interfere with the efficiency of either admixture or adversely affect
the concrete.
(6) Calibration
All laboratory equipment and batch plant equipment shall be calibrated regularly in accordance with
Indonesian Regulation and ACI 304R.
3.2 Production by In-Situ Concrete Mixer

In-Situ Concrete Mixer may be used for concreting work that can be completed by 1 batch basically.
In-Situ Concrete Mixer shall not be used without KJP’s approval.
3.3 Concrete Production for Early Activity
_ __ For Early Activity such as Camp and GPFSB Construction, Subcontractor may propose a Batcher Plant
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3.4 Durability
(1) Normal weight concrete required being watertight shall have a water-cement ratio not exceeding 0.50if
exposure will be to fresh water or 0.4 for exposure to seawater, per Table 4.2.2. of ACI318.
(2) The maximum concentration of water soluble chloride ions (Cl-) accumulated in the concrete by all of
the ingredients including water, aggregates, cement and admixtures shall not exceed the values (percent
by weight of cement) stipulated in ACI 318, Table 4.4.1.
(3) The total water-soluble sulfate content of the concrete mix expressed as SO3 should not exceed 4% by
mass of the cement in the mix and ACI318 requirement.
(4) Concrete exposed to sulphate-containing solutions shall follow the requirements of ACI 318 Table
4.3.1
3.5 Slump
Unless otherwise specified, ACI211.1 shall be referred to for recommended slumps for various types of
construction. The slump shall be determined in accordance with ASTM C143.
4. REINFORCEMENT
4.1 Material
Steel reinforcement shall conform to the requirements of JIS G3112 SD390, ASTM A615 Grade 60 or
equivalent. Steel welded wire fabric shall conform to the requirements of ASTM A185 or equivalent.
Reinforcement shall satisfy the followings as per ACI318: -

(a) The actual yield strength based on mill tests does not exceed the specified yield strength by more than
120MPa (retests shall not exceed this value by more than an additional 20MPa; and
(b) The ratio of the actual ultimate tensile strength to the actual tensile yield strength is not less than 1.25.
4.2 Fabrication & Placing

4.2.1 General
Details of concrete reinforcement and accessories not covered herein shall be in accordance with ACI 315.
4.2.2 Fabrication
(1) Welding of reinforcing bar shall be avoided.
(2) General construction details and workmanship relative to reinforcement, including bar bends, lap splices
and installation, shall be in accordance with ACI 318, Chapters 7 and 12. Unless otherwise noted, all lap
splices of deformed bars and deformed wire in tension shall be Class B.
4.2.3 Placing
(1) Reinforcing bars shall be free from mud, dirt, loose rust, loose mill scale, oil, grease, and any other
foreign matter that may reduce the bond between bars and concrete.
(2) All reinforcement shall be supported and fastened together to prevent displacement beyond the required
tolerances due to construction loads or the placing of concrete. Reinforcing bars shall be supported by
_ __ pre-cast concrete/mortar blocks having a compressive strength not less than the specified compressive
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their placement shall conform to both the CRSI Manual of Standard Practice, Chapter 3, and ACI 301.
(3) Splices in reinforcement shall be made and located as called for on the drawings, in the construction
notes, or as otherwise approved. Splices in adjacent bars shall be staggered.
5. CONCRETING
5.1 Blinding Concrete

All reinforced concrete foundations shall be constructed on plain concrete blinding. Thickness of blinding
shall be a minimum of 50 mm, and it will provided 50 mm outside the foundation perimeter.
5.2 Formwork
5.2.1 General
(1) Requirements for formwork not covered herein shall be in accordance with ACI 347R.
(2) Forms shall have sufficient strength to withstand the pressure resulting from placement and vibration of
the concrete, and shall have sufficient rigidity to maintain specified tolerances.
(3) The forms material for concrete material expose to view shall produce smooth, hard and uniform texture
on the concrete unless different texture requirement shown on the drawings.
5.2.2 Design and Installation of Formwork

(1) Forms shall be sufficiently tight to prevent loss of mortar from the concrete. Chamfer strips shall be
placed in the comers of forms to produce 20 mm chamfer beveled edges on permanently exposed
surfaces. Chamfer strips are not required on interior corners of such surfaces, the edges of formed joints,
tops of piers supporting horizontal vessels, and concrete edges providing direct support for flooring, or
to which steel will be attached for flooring support.
(2) Temporary openings shall be provided at the base of column forms and wall forms and at other points
where necessary to facilitate cleaning and inspection immediately before concrete is placed.
(3) Positive means of adjustment (wedges, jacks, etc.) of shores and struts shall be provided and all
settlement shall be taken up during concrete placing operation. Forms shall be securely braced against
lateral deflections.
5.2.3 Preparation of Form Surface

(1) All surfaces of forms and embedded materials shall be cleaned of all accumulated mortar or grout from
previous concreting and of all other foreign material before concrete is placed.
(2) Before placing the reinforcing steel or the concrete, the surfaces of the forms shall be covered with an
acceptable coating material that will effectively prevent absorption of moisture, prevent bond with the
concrete, and not stain the concrete surfaces. A field applied form release agent or sealer of acceptable
type or factory applied non-absorptive liner may be used. Care shall be taken that the parting agent does
not get on concrete or reinforcement, which is to bond with new concrete.
5.2.4 Removal of Forms

(1) Removal of forms and supports shall be in accordance with ACI 347.
(2) When repair of surface defects or finishing is required at an early age, forms shall be removed as soon as
the concrete has hardened sufficiently to sustain the load and resist damage from removal operations.
_ __ (3) Formwork for columns, walls, sides of beams and other parts not supporting the weight of the concrete
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may be removed as soon as the concrete has hardened sufficiently to resist damage from removal
operations.
Forms and shoring in the formwork used to support the weight of concrete in beams, slabs and other
structural members shall remain in place until the concrete has reached the required strength to support
the weight of concrete and anticipated imposed loads. Field-cured specimens shall be used to estimate
the strength of concrete. When fieldcured specimens can not be used to determine the time of the form
removal, forms and shoring shall be remain in place for a period of time not less than that specified in
ACI 347R.
Walls : 12 hours (Note 1)

Columns and Pedestals : 12 hours (Note 1)
Sides of Beams, Girders and Footings : 12 hours (Note 1)
Joist, Beam or Girder Soffits:
Beams perpendicular to Main Pipe Track or Equipment Supporting : 14 days (Note 2, 3)
Other Beams : 21 days (Note 2, 3)
Note 1 : Where such support formwork for slab or beam soffits, the removal times of the latter should
govern.
Note 2 : In the case that design strength of concrete is confirmed by crushing test at 7 days, formworks
may be removed.
Note 3 : Where forms may be removed without disturbing shores, use half values shown.
(4) When forms are removed before the end of the required curing period, the concrete shall be cured after
removal of the forms by suitable methods.
5.3 Fabrication and Placing of Reinforcement

See Section 3.2.
5.4 Anchor Bolts and Embedded Items

(1) All sleeves, inserts, anchors, and embedded items shall be placed prior to concrete pouring. Voids in
those embedded items shall be filled temporarily with readily removable material to prevent the entry of
concrete into the voids.
(2) Anchor bolts and other embedded items shall be cleaned of undesirable coatings, such as scale, grease,
or dirt that would be detrimental to bonding with concrete.
(3) Anchor bolts shall be placed inside the "cages" of reinforcing bars.
(4) Other embedded items shall be installed as shown on design drawings and they shall be supported
against displacement during placement and consolidation of concrete.
(5) Top of anchor bolt sleeves, if any, shall be cut off flush with rough concrete just prior to grout or
equipment installation.
5.5 Waterstop
(1) The material and location of water-stops in joints shall be in accordance with the construction drawings.
_ __ (2) Water-stop material shall confirm to CRD-C572 (U.S. Army Corps of Engineers Handbook of Concrete
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and Cement) for polyvinylchloride water-stop, or equivalent.

(3) Water-stops shall be installed per ACI 301, Section 2.2
5.6 Joint
5.6.1 Construction Joint
(1) Construction joints shall be made as shown on the drawings and per ACI 301. Construction Joints not
indicated on the construction drawings may be provide at Subcontractor's option, except that they must
meet the requirements of ACI 301. Joints shall be perpendicular to the main reinforcement.
(2) Construction shall not be made in horizontal framing members unless called for on the drawings.
Construction joints in elevated slabs should be located preferably at mi span between adjacent
supporting members.
(3) The surface of the concrete at all joints shall be rough, thoroughly cleaned and all laitance shall be
removed prior to placing adjoining concrete. The laitance shall be removed by brushing, chipping, wet
sandblasting or high pressure water-blasting down to sound mortar matrix, leaving clean, sound
aggregate exposed over the entire joint surface, but not undercutting the large aggregate particles. The
surface of the concrete shall then be washed thoroughly to remove all loose material.
(4) All concrete joint surfaces to receive new concrete shall be free of surface water but shall be in a
saturated surface dry condition. Construction joints of which strength is critical against shear, or which
requires water-tightness should be covered with 12mm mortar immediately before the concrete placing,
or provided with keys having 1/3 width of the smallest joined member and 50mm depth.
5.6.2 Expansion Joint

(1) Expansion joints shall be made as shown on the drawings and per ACI 301.
(2) Expansion joints shall extend the full width and depth of the concrete section.
(3) Expansion joint filler material shall conform to ASTM D994, ASTM D1751 or ASTM D1752.
5.6.3 Contraction Joint

Contraction Joint shall be made straight and uniform by forming, tooling or sawing. The sealer material and
their application shall confirm to ASTM D1190.
5.7 Placing of Concrete

5.7.1 Transportation
(1) Concrete shall be transported from Batch Plant to discharge locations by methods which prevent
segregation, loss, or contamination of concrete ingredients so as to assure that the required quality of the
concrete is maintained.
(2) A time for transportation from the time of adding cement till the final pouring shall not exceed good
concrete setting time determined during trial mixing
(3) Aluminum and aluminum alloy material shall not be used in conveying equipment, including trucks,
pump lines, tremies, chutes, etc. Short pump lines, tremies and chutes to remove concrete from transit
truck mixers are excluded.
5.7.2 Placing
(1) Hardened concrete and foreign materials shall be removed from the inner surfaces of the conveying
equipment.
(2) All below ground concrete should be placed on a layer of blinding concrete.. In dry weather, any soil on
_ __ which concrete is to be placed shall be moistened immediately before placing the concrete. Concrete
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shall not be placed in standing water.

(3) Prior to placing concrete the reinforcement shall be secured in place, the embedded items shall be
positioned and the interior of all forms shall be thoroughly cleaned and made free from all foreign matter
and accumulated water. The interior of wooden forms shall be wetted prior to concrete placing. The
entire preparation shall be accepted by KJP.
(4) To minimize segregation, the concrete shall be deposited at a position as near as possible to its final
position.
(5) The placement rate shall be such that the concrete will remain plastic at all times, and will flow readily
into all spaces between the reinforcing bars, etc.
(6) Concrete that has partially hardened or has been contaminated by foreign matter shall not be used.
(7) Once placement has started, it must be carriedcaned out continuously until the placing of the concrete
for that panel or section is completed.
(8) The drop height for the concrete shall not exceed 1.5 meters. Temporary openings shall be provided for
tall forms to reduce the drop height and to enable easy vibration. To ensure sufficient vibration, concrete
shall be placed in horizontal layers not exceeding 0.6 m in depth; care must be taken to ensure that the
top surface of each layer is horizontal.
(9) Unless otherwise specified, all concrete shall be thoroughly consolidated by vibrators during placing.
The vibrators shall be inserted in a vertical direction into the concrete, and care shall be taken to ensure
that the concrete is thoroughly worked around the reinforcement, anchor bolts and other embedded
fixtures, and into the comers of the forms. A proper number of spare vibrators shall always be kept at the
site during all concrete placing operations. Vibration equipment shall not be used to move concrete
within the forms.
(10) Concrete placing for large or lengthy foundations and structures shall be so performed as to avoid cold
joints.
(11) Unless adequate protection of the concrete is provided until it has hardened sufficiently so that it will not
be damaged and acceptance from KJP is obtained, concrete shall not be placed during rain.
(12) Concrete for drilled piers shall be placed before the end of the day the piers are drilled.
5.8 Finishing
(1) Finished slab surfaces shall be true plane surfaces. Slab surfaces shall be constructed with a tolerance of
6 mm in 3 m unless otherwise indicated. Surfaces shall be pitched to drains, as required. Finish to be
provided shall be as called for on the drawings and shall conform to the following requirements.
(2) Steel trowel finish shall be finished by tamping the concrete with a wire mesh tamper to depress the
coarse aggregate sufficiently to bring the matrix fines to the surface, then screeding and striking with
straight edges to bring the surface to the required finished level. While the concrete is still green, but
sufficiently hardened to bear a man's weight without excessive imprint, it shall be floated either by hand
or mechanical means to a true, even plane, with no coarse aggregate visible. Sufficient pressure shall be
used on the float to bring moisture to the surface. After surface moisture has disappeared, the surface
shall be machine or hand troweled to a smooth, even finish.
(3) Wood Float finish shall be provided by screeding to the required level with a straight edge and finished
with a wood float.
(4) Screeded finish shall be provided by screeding to the required level with a straight edge only.
(5) Heavy broomed finish for vehicular traffic is to have a wood float finish, followed by brooming with a
heavy broom, producing patterns perpendicular to traffic.
(6) Surfaces designated for foot traffic are to receive a light broomed finish. They are to receive a steel
trowel finish, followed by brooming after completion of the troweling with a horsehair bristle brush or
light broom in a direction perpendicular to the main line of traffic.
_ __ (7) Surfaces indicated to have abrasive finishing shall be finished as specified for trowel finish, immediately
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following which, an abrasive material shall be evenly applied to the surface at a rate of not less than 0.1
kg of abrasive material to each square foot of surface. The surfaces shall then be hand steel troweled.
(8) When concrete is to be left with the surface finish imparted to it by the forms, objectionable irregularities
shall be removed
(9) Top surfaces of concrete below finished grade shall be screeded to the specified elevation, tamped with
a grid tamper and given a wood float finish.
(10) Unless otherwise specified on drawings, top surfaces of concrete foundations on which grout will be
installed shall be rough-finished to an elevation of 25 mm to 75 mm below finished elevation.
5.9 Curing
5.9.1 General
(1) Requirements for curing and protection of concrete not covered herein shall be in accordance with ACI
308.
(2) Beginning immediately after placement, concrete shall be protected from premature drying, excessively
hot temperatures, and mechanical injury, and shall be maintained with minimal moisture loss at a
relatively constant temperature for the period necessary for hydration of the cement and hardening of the
concrete.
5.9.2 Moisture Retention

(1) For concrete surfaces not in contact with forms, one of the following procedures shall be applied
immediately after completion of placement and finishing:
• Ponding or continuous sprinkling.
• Application of absorptive mats or fabric kept continuously wet.
• Application of sand kept continuously wet.
• Application of sheet materials conforming to ASTM C171. The sheets shall be lapped
not less than 100 mm at edges and ends and be sealed with adhesive or pressure
sensitive tape no less than 40 mm in width. The membrane shall be weighted to prevent
displacement. Holes appearing in the membrane during curing period shall be
immediately patched. The membrane shall remain intact for not less than the curing
period in 5.9.2(3).
• Application of other acceptable moisture-retaining covering.
• Application of a curing compound conforming to ASTM C 309.
The curing water used in the above methods shall be clean and free of contaminating
substances that will discolor the concrete.
(2) Moisture loss from surfaces placed against wooden forms or metal forms exposed to heating by the sun
shall be minimized by keeping the forms wet until they can be safely removed. After form removal the
concrete shall be cured until the end of the time prescribed in Section 5.9.2 (3) by one of the methods of
Section 5.9.2 (1).
(3) Curing in accordance with this section shall be continued for at least 7 days in the case of all concrete
except high-early-strength concrete, for which the period shall be at least 3 days.
(4) Abrupt changes in the temperature of the concrete shall be prevented.
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5.9.3 Protection from Mechanical Injury

The concrete shall be protected from damaging mechanical disturbances, such as load stresses, heavy shock,
and excessive vibration. All finished concrete surfaces shall be protected from damage by construction
equipment, materials, or methods, by application of curing procedures, and by rain or running water.
Self-supporting structures shall not be loaded in such a way as to overstress the concrete.
6. REPAIR OF SURFACE DEFECTS
(1) Defects of concrete such as honeycombing, cracking or condition(s) detrimental to strength, stability,
durability and water tightness of the concrete shall be repaired immediately after form removal per ACI
301, Section 5.3.7 or by approved repair procedure. All defects shall be removed down to a sound
surface. Curing procedures shall not be delayed or interrupted while making repairs. Prior to repair of
defects, it shall be notified to KJP.
(2) Holes left by the withdrawal of tie-rods shall be filled solid with cement mortar and the ends made flush
with the adjoining surface. It is recommended to refrain from using hole-through tie rods for liquid
retaining structures.
7. PROTECTION OF UNDERGROUND CONCRETE
7.1 General
Concrete shall be made so that it will perform satisfactorily when exposed to various atmospheric conditions,
to waters and soils containing chemicals, and to other kinds of chemicals. Chemical attack on concrete is
generally the result of exposure to sulfates or acids.
Such environmental conditions shall be taken into consideration for concrete mix designs and application of
protective coatings on concrete surfaces to ensure the required durability of concrete.
7.2 Material
Asphalt, coal tar, coal tar epoxy, bituminous based coating materials are acceptable for concrete surfaces
contacting soil.
Surface coating materials and application to underground foundations shall meet the following
definition and material vendor catalogues, Attachment-1.
7.2.1 Foundations in Severe Zone

Cement Type: Type-V 900-TM-KJPJ_
BPJ-324
w/c ratio: max.0.45
Sheet barrier: Plasticized PE sheet (0.2mm thick.), with sealing tape
Coating: Chemical resistant impermeable coating, Nitocote-PE-135 or ET402 from Fosroc or
equivalent
7.2.2 Foundations in Mild Zone

Cement Type: Type-V
w/c ratio: max. 0.45
_ __ Sheet barrier: no sheet

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Coating: Bitumen, Coal tar, epoxy coating or equivalent
7.2.3 Foundations in Low Corrosive Zone, (this paragraph is not a part of 900-TM-KJPJ_BPJ-324)
Cement Type: Type-V
Sheet barrier: no sheet
Coating: no coating
7.2.4 Pile (manufactured at shop, PT. Pacific Pre-stress Indonesia)

Cement Type: Type-V
Manufacturing: JIS-A-5335, Pre-stressed Concrete Span Pile
Mechanical Property: Concrete Strength 600kglcm2 (Cube test at 28 days)
Coating: no coating
7.2.5 LNG Tank Foundations

Cement Type: Type-V 900-TM-KJPJ_
BPJ-398
Coating: Chemical resistant impermeable coating, Nitocote-PE-135 or ET402 from
Fosroc or equivalent
7.3 Application
(1) The application procedure of a coating including surface preparation of concrete, weather restrictions, a
minimum thickness, number of coats, curing, inspection, and repair methods shall comply with
recommendations and instructions given by the coating manufacture/supplier. Subontractor shall submit
a method statement for KJP's approval.
(2) Proper concrete surface preparation is essential for good performance of the coating. The surfaces of
concrete should be free of oil, grease, dirt, loose, weak and unsound materials. The recommendation for
concrete surface preparation given by the coating material manufacturer should be followed.
(3) Appropriate safety requirements should be followed with respect to the coating material characteristic,
operations, procedures described in the instruction given by the manufactures.
(4) Surface Coating Extent and its grade shall follow the specification S-900-1310-301, Surface
Coating Extent for Underground Foundations and related design drawings.
8. PRECAST CONCRETE
8.1 Production
(1) No precast members leave the works unless they have reached the appropriate hardening phase and they
are marked in compliance with the hereafter section.
(2) Precast members shall be free from damage liable to adversely affect their structural performance.
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(4) If precast members are left to harden in the open air, arrangements shall be made to protect them from
adverse weather conditions.
8.2 Transportation and Delivery

During transportation precast members shall not be overstressed, warped, or otherwise damaged or have
camber adversely affected.
8.3 Erection and Assembly

(1) Precast members shall be adequately braced and supported during erection to insure proper alignment
and structural integrity until permanent connections are completed.
(2) Mechanical Joint for rebar joint shall be Type-II in UBC. Refer to each design drawing for the detail.
(3) In their final portion, precast members shall be set in non-shrink grout or concrete at the supports.
(4) Prior to erection, rigging study shall be done and submitted for KJP’s approval.
9. HOT WEATHER CONCRETE
Concrete work is significantly affected by high temperatures in the concrete and in the air, or by a low
relative humidity, or by a high wind velocity. If these conditions are prevalent, the concrete work shall be
carried out in accordance with the requirements of ACI 305R, and the following:
Where the concrete temperature exceeds 32 °C, necessary preventive measures, as noted below, shall be
taken. However, if the rate of evaporation from the concrete surface as determined by ACI 305R is less than
1.0 kgf/m2/h that no preventive measures are required even when the concrete temperature exceeds 32 °C. In
no case shall the concrete temperature exceed 38 °C. Exceeding the limiting water-cement ratio in order to
have sufficient slump for placing at concrete temperatures between 32 °C and 38 °C shall not be permitted.
Instead, the preventive measures noted below will be used to increase the slump.
The following preventive measures shall be taken to avoid the adverse effects of hot weather
(a) Adding water-reducing and retarding admixture to concrete.

(b) Using chilled water for mixing.
(c) Painting storage facilities, batching plants, pipes, and agitating trucks white or
silver and/or insulating the same.
(d) Keeping the transportation time to a minimum.
(e) Checking mixer drums and blades frequently during hot weather, and ensuring that
the interior of the mixer is free of any accumulated matter that will interfere with the
mixing action.
(f) Providing sufficient equipment and workers to ensure quick placing and finishing,
and so as to avoid cold jointing and plastic shrinkage cracking. All plans for the
arrangement of the equipment and workers shall be submitted to KJP for approval.
_ __ (g) Using a white pigmented material when a curing compound is applied.
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(h) Shading materials and facilities from the direct rays of the sun.
When the measures given in Section 8.4.2 are considered insufficient to avoid the adverse effects of hot
weather, the following additional measures may be taken:
(a) Carrying out concrete placing in the evening, at night, or in the early morning
(b) Spraying water onto the aggregate and considering new w/c ratio on design mix.
(Any water in the aggregate must be accounted for in the water-cement ratio.)
(c) Providing wind breaks during concrete placing
(d) Using flaked ice as a part of the mixing water
10. MASS CONCRETE
When the concrete is considered as massive concrete, ACI 207.1R should be referred to.
11. INSPECTION AND TEST
11.1 Construction Tolerance

11.1.1 General
Tolerance shall be based on ACI 117, ACI315 and ACI 347 in case not specified in this section or unless
otherwise specified in the design drawings.
11.1.2 Concrete
Items to be measured Tolerance

Variation from the plumb: ± 6mm in any 3m.
(In the lines and surface of columns, piers and walls.) ±25mm for entire length.
Variation of the finishing level of Elevated Slab. ±20mm for entire length.
Variation of the finishing level of Surfaces to be grouted. ± 6mm.
Variation of the finishing level of Floors. ± 6mm in any 3m.
±10mm in any bay or in any 6m of length.
±20mm for entire length.
Variation in the thickness of slabs and walls and in the - 6mm
cross-sectional dimensions of beams and columns.
+12mm
Misplacement of eccentricity of Footing. 2% of width in the direction of
misplacement but not more then 50mm.
Decrease of specified thickness of Footing. Less than 5% of specified thickness.
Table-1
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11.1.3 Reinforcement
(1) Clear distance to formed surfaces:
The definition of clear distance is referred to Section 2.2.2 of ACI 117.
Member Size Tolerance
4 in. or less. + 1/4 in. + 7mm
- 3/8 in. - 10mm
Over 4 in. but not over 12 in. 3/8 in. 10mm
Over 12 in. but not over 2 ft. 1/2 in. 13mm
Over 2 ft. 1 in. 25mm
Table-2
(2) Concrete cover measured perpendicular to concrete surface:

Member Size Tolerance
12 in. or less. - 3/8 in. - 10mm
Over 12 in. - 1/2 in. - 13mm
Table-3
(3) Distance between reinforcement:

1/4 of specified distance not to exceed 1 in.
The minimum clear spacing between parallel bars on a layer shall be nominal diameter of rebar and 4/3
times of nominal maximum size of coarse aggregate, but not less than 25mm.
11.1.4 Anchor Bolts & Embedded Items

(1) Anchor Bolts
Item to be measured. Tolerance
Bolt Projection + 1/4 in. + 7mm
- 0 in. - 0mm
Bolt Location (without sleeves) ± 1/8 in. ± 3mm
Bolt Location (with sleeves) ±3/16 in. ± 5mm
Table-4
(2) Group of Anchor Bolts
Steel Structure (Shelters, Buildings, Piperacks and the like)
Deviation of Group Anchor Bolts from the Alignment
shown on the drawings.
Columns/Posts in 5m
± 3/16 in. ± 5mm
Columns/Posts in more than 5m
± 3/8 in. ± 10mm
Equipment and Vessels
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position shown on the drawings. ± 3/16 in. ± 5mm
(3) Embedded Items

Increnation from true in any direction 1/200
Offset ± 3/16 in. ± 5mm
Elevation ± 3/16 in. ± 5mm
Table-6
11.2 Inspection and Test

11.2.1 General
Inspection and test shall confirm to ACI311 if not specified in this section.
Also please refer to S-900-1520-105 “Inspection and Test Plan for Concrete Work”
11.2.2 Sampling for Test

The sampling and slump test of freshly mixed concrete shall be performed at the point of delivery.
11.2.3 Slump Test

The slump tests shall be carried out in accordance with the following:
• All slump test shall be carried out in accordance with the requirement of ASTM C143.
• Slump test shall be performed at each delivery of concrete.
• The result of the tests shall show that the slump is within the range specified in the construction
drawing, or the concrete shall not be placed.
The temperature of fresh concrete shall also be checked at the time of slump test.
11.2.4 Compressive Strength Test

Compressive strength tests shall be carried out for each class of concrete, in accordance with the following
procedures:
(1) Samples of concrete for making compressive strength test specimens shall be obtained in accordance
with the requirements of ASTM C 172.
(2) A minimum of 3 specimens shall be molded and cured in accordance with the requirements of ASTM C
31.
(3) Compressive strength tests of cylinders shall be carried out in accordance with the requirements of
ASTM C 39. These cylinders shall be tested as follows:
• One at 7 days for information
• Two at 28 days for determining acceptability of concrete strength
Evaluation and acceptance of concrete shall be in accordance with ACI 318.
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Samples shall be taken from each complete pour for individual foundations or structures supporting main
processing units, heavy mechanical equipment, buildings, storage tanks, and from other important concrete
structures. At least two samples shall be taken from each full days concreting or not less than required by the
following.
No. of Cubic Meters in Any No. of Samples To be Taken

Individual Foundation or Structure (3 Cylinders per Sample)
0-38 One for each 20 cubic meters
39 –150 One for each 40 cubic meters
151 - 270 One for each 60 cubic meters
Greater than 270 One for each 75 cubic meters
11.2.5 Air Content Test

Air content tests shall be performed when the concrete samples are taken, and in accordance with the
requirements of ASTM C 138, ASTM C 173, or ASTM C 231. Determine temperature of concrete sample for
each strength test.
11.2.6 Water Filling Test for Concrete Ponds/Pits

For concrete ponds/pits that are designed to retain contaminated water such as oil and chemicals, a water-
filling test shall be carried out before back filling of the pond. A water-filling test is not required for seawater
or cleans water ponds unless the high water level is higher than ground elevation. Water shall be filled to the
design high water level, a minimum of 24 hours before the inspection is due. Concrete ponds shall be back
filled only after obtaining the approval of KJP.
The acceptance criterion for water filling test is that no water leak is observed on the external surface of the
concrete pit. If the leakage is found, the defected parts shall be repaired according to the section 6
above, then inspect the parts again until no leakage is observed.
Fresh water shall be used for the test.
11.3 Test Report

All test report shall be submitted to KJP upon completion of test.
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Construction Spec For Concrete Work

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Doc. No. 900-SPE-RC0-1001 Rev.

Construction Specification for Concrete Work

Attachment – 1 : Technical Information of Coating Material for Underfround Concrete

X Core Non-core Lifecycle Code B

Rev. Date Page Description Prep’d Chk’d App’d BP App’d

1.2.2 Project Specifications

1.3 Conflict in Requirement

2.1.3 Rejection of Cement Material

Maximum size of coarse aggregate is 20mm.

The source of material shall not be changed without KJP’s approval.

2.3 Mixing Water

Water shall have a pH between 5.0 and 8.5.

3.1 Production by Batch Plant

3.1.2 Facility Requirement

3.1.3 Measuring and Batching

(2) Accuracy of Scales

(3) Accuracy of Batching

(5) Control of Admixtures

3.2 Production by In-Situ Concrete Mixer

3.3 Concrete Production for Early Activity

Reinforcement shall satisfy the followings as per ACI318: -

4.2 Fabrication & Placing

5.1 Blinding Concrete

5.2.2 Design and Installation of Formwork

5.2.3 Preparation of Form Surface

5.2.4 Removal of Forms

Walls : 12 hours (Note 1)

5.3 Fabrication and Placing of Reinforcement

5.4 Anchor Bolts and Embedded Items

and Cement) for polyvinylchloride water-stop, or equivalent.

5.6.2 Expansion Joint

5.6.3 Contraction Joint

5.7 Placing of Concrete

shall not be placed in standing water.

5.9.2 Moisture Retention

5.9.3 Protection from Mechanical Injury

6. REPAIR OF SURFACE DEFECTS

7. PROTECTION OF UNDERGROUND CONCRETE

7.2.1 Foundations in Severe Zone

7.2.2 Foundations in Mild Zone

_ __ Sheet barrier: no sheet

Coating: Bitumen, Coal tar, epoxy coating or equivalent

7.2.4 Pile (manufactured at shop, PT. Pacific Pre-stress Indonesia)

7.2.5 LNG Tank Foundations

8.2 Transportation and Delivery

8.3 Erection and Assembly

9. HOT WEATHER CONCRETE

(a) Adding water-reducing and retarding admixture to concrete.

_ __ (g) Using a white pigmented material when a curing compound is applied.

10. MASS CONCRETE

11. INSPECTION AND TEST

11.1 Construction Tolerance

Items to be measured Tolerance

(2) Concrete cover measured perpendicular to concrete surface:

(3) Distance between reinforcement:

11.1.4 Anchor Bolts & Embedded Items

position shown on the drawings. ± 3/16 in. ± 5mm

(3) Embedded Items

11.2 Inspection and Test