TABLE OF CONTENTS

Description Page No.

PART 1: OFF-SITE BATCHING PLANT 2

1) Method Statement on Concrete Mix Design for MHI/ZACL for
3-6
Offsite Batching Plant
2) Appendix 1 (Materials Test Certificates) 7-27
3) Appendix 2 (Concrete Design Mixes, M1 to M7) 28-30
4) Appendix 3 (Results of Lab Trial Mix for M4) 31-33
5) Appendix 4 (Plant Equipment Calibration Certificates) 34-46
6) Appendix 5 (Request For Inspection & Plant Trial Mix Results
47-52
for M4)
PART 2: PROPOSED SITE BATCHING PLANT 53

1) Introduction 54
2) Proposed Site Batching Plant & Layout 54
3) Plant Facilities & Equipment 54
4) Sources of Raw Materials for Concrete Production 55
5) Temperature Control System 55
6) QA/QC Implementation Plan 55
7) Plant Safety, Health Policies, & Practices
55

8) Risk Assessment 56
PART 3: INDEPENDENT LABORATORY COMPANY
56
PROFILE FOR CONCRETE
ANNEXES:
a) ANNEX 1 : Proposed Batching Plant Location Plan 57-58
b) ANNEX 2 : Proposed Batching Plant Detailed Layout with
Logistic Route, and Logistic Requirement for 59-61
Peak concrete consumption in October ‘08
c) ANNEX 3 : Supplier Plant Brochure 62-66
d) ANNEX 4: Materials test certificates for materials not
67-76
included in Part 1.
e) ANNEX 5 : Organization Chart & QA/QC Check List 77-79
f) ANNEX 6: RGF’s Company Profile & past experiences in
80-177
concrete mix design

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SHUQAIQ II IWPP

1. CONCRETE DESIGN MIX FOR OFFSHORE STRUCTURES

1. Mix reference Discharge Channel Seawater Intake Fuel Oil Unloading

Box Culvert Jetty
M5 M6 M7
2. Strength grade at 28-day (Mpa)
Cube Strength 45 45 45
Cylinder Strength 35 35 35
3. Maximum size of aggregate, mm 20 20 20

4. Types of aggregate BS 882 BS 882 ASTM C33

Sand BS 882 BS 882 ASTM C33

5. Cement type(s) or combinations PC (4%≤C3A≤10%) PC (4%≤C3A≤10%) PC (4%≤C3A≤10%)

complying with BS 12/ (with 7.5% Silica (with 5.0% Silica (with 7.5% Silica
ASTM C150 Type I Fume) Fume) Fume)

6. Minimum cement content, kg/m³ 375 375 375

7. Maximum free water/cement 0.42 0.42 0.40

ratio
8. Quality assurance requirements Refer to Method Refer to Method Refer to Method
Statement for Statement for General Statement for General
General Concrete Concrete Works Concrete Works
Works
9. Rate of sampling Refer to Test & Refer to Test & Refer to Test &
for strength testing Inspection Plan for Inspection Plan for Inspection Plan for
Civil Work Civil Work Civil Work

10. Other requirements :

10.1 Maximum chloride content not exceed 0.15% if not exceed 0.15% if not exceed 0.15% if
C3A is less than 4%, C3A is less than 4%, C3A is less than 4%, or
or or not exceed 0.3% if C3A
not exceed 0.3% if not exceed 0.3% if is 4% or more.
C3A is 4% or more. C3A is 4% or more.

10.2 Temperature (at the point of 35 ºC 35 ºC 35 ºC

delivery, max. ºC)

10.3 Density (max./min.kg/m³) 2400/2300 2400/2300 2400/2300

10.4 Admixtures To comply with To comply with To comply with

BS 5328: Part 1 & BS 5328: Part 1 & ASTM C494
BS EN 480 BS EN BS EN 480 BS EN
934 934
10.5 Air content (max, %) 5 5 5

10.6 Max. cement content (kg/m3) 500 500 500

10.7 Max drying shrinkage of 0.05 0.05 0.05

aggregate

11. Workability ~ Slump, mm 100 ± 25 100 ± 25 100 ± 25

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SHUQAIQ II IWPP

2. CONCRETE DESIGN MIX FOR ONSHORE STRUCTURES

1. Mix reference Lean and Filling Concrete Structural Concrete

M1 M2 M3 M4
2. Strength grade at
28-day (Mpa)
Cube Strength 15 20 30 45
Cylinder Strength 12 16 25 35
3. Maximum size of
aggregate, mm 20 20 20 20

4. Types of aggregate ASTM C33 ASTM C33 ASTM C33 ASTM C33
/ Sand ASTM C33 ASTM C33 ASTM C33 ASTM C33

5. Cement type(s) or Portland Cement Portland Cement PC PC

combinations complying (PC) (PC) (4%≤C3A≤10%) (4%≤C3A≤10%)
with BS 12/ ASTM C150 (with 7.5% Silica (with 7.5% Silica
Type I Fume) Fume)
6. Minimum cement None None 275 375
content, kg/m³
7. Maximum free None None 0.45 0.42
water/cement ratio
8. Quality assurance Refer to Method Refer to Method Refer to Method Refer to Method
requirements Statement for Statement for Statement for Statement for
General Concrete General Concrete General Concrete General Concrete
Works Works Works Works

9. Rate of sampling Refer to Test & Refer to Test & Refer to Test & Refer to Test &
for strength testing Inspection Plan Inspection Plan Inspection Plan Inspection Plan
for Civil Work for Civil Work for Civil Work for Civil Work

10. Other requirements :

10.1 Maximum chloride not exceed 0.15% not exceed 0.15% not exceed 0.15% not exceed 0.15%
content if C3A is less than if C3A is less than if C3A is less than if C3A is less than
4%, or 4%, or 4%, or 4%, or
not exceed 0.3% not exceed 0.3% not exceed 0.3% not exceed 0.3%
if C3A is 4% or if C3A is 4% or if C3A is 4% or if C3A is 4% or
more. more. more. more.

10.2 Temperature (at the 35 ºC 35 ºC General : 35 ºC General : 35 ºC

point of delivery, Mass Conc.: 30oC Mass Conc.: 30oC
max. ºC)
10.3 Density 2400/2300 2400/2300 2400/2300 2400/2300
(max./min.kg/m³)
10.4 Admixtures To comply with To comply with To comply with To comply with
ASTM C494 ASTM C494 ASTM C494 ASTM C494
10.5 Air content (max, None None 5 5
%)
10.6 Max. cement content None None 500 500
(kg/m3)
Max drying shrinkage of 0.05 0.05 0.05 0.05
aggregate
11. Workability ~ Refer to Test & Refer to Test & Refer to Test & Refer to Test &
Slump, mm Inspection Plan Inspection Plan Inspection Plan Inspection Plan
for Civil Work for Civil Work for Civil Work for Civil Work

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file:///D|/Method Statements/MS for Concrete Supply/MS For Concrete Supply (Rev-0)/IMGP0664_JPG.htm

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file:///D|/Method Statements/MS for Concrete Supply/MS For Concrete Supply (Rev-0)/IMGP0664_JPG.htm10/1/2007 2:45:51 PM
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PART 2: PROPOSED SITE BATCHING PLANT

1) INTRODUCTION

The batching plant structure and equipment, consisting of three (3) Batching
Plant Units, (2-Operational, & 1-back-up) with a combined capacity of 300
Cu.M. per Hour. The first unit (60 Cu.M/hr. capacity, will be operational by end of
October, 2007. The 2nd & 3rd units with capacity of 120 Cu.M./Hr per unit, will be
supplied by an Italian firm, O.Cuoghi (website: www.cuoghisas.it).

2) PROPOSED SITE BATCHING PLANT LOCATION AND LAYOUT

The batching plant structure and equipment, consisting of three (3) Batching
Plant Units, (2-Operational, & 1-back-up), will be erected north of Zelan’s staff
camp (Pls. see attached site plan and proposed Batching Plant layout with
Logistic Route, and Logistic Requirement for peak concrete consumption in
October 2008, Annexes “1” & “2”).

3) PLANT FACILITIES & EQUIPMENT:

a) Three (3) Batching Plant Units (Model No. 2250/150 for 1st unit);
Model No.:4500/3000 for 2nd & 3rd Units)
b) Rated hourly output wet compacted concrete production (1st Unit= 60
Cu.M./Hr)
Rated hourly output wet compacted concrete production for 2nd and 3rd
Unit = 120 Cu.M./Hr per unit), with plant configuration marked “B” in
the attached brochure marked as Annex “3”.
c) Five (5 ) aggregates compartment storage group = 100 Cu.M.capacity
per unit
d) Maximum output per batch cycle, compacted concrete = 3 Cu.M.
e) Aggregate weighing hopper (4 load cells ) = 10 MT capacity
f) Cement weighing hopper = 2MT capacity
g) Aggregates Storage Spray system
h) Truck Mixers (Minimum 8 nos.)
i) Mobile pump trucks (Brand: Schwing, Max. range=42M) = 4 Nos.
j) Chilled Water Tank Facilities (2 Nos.)
k) Water Storage Tanks for concrete batching
l) Water Storage tanks for aggregate washing/spraying
m) Mobile water trucks (Min. 3 Nos.)
n) Plant office
o) Laboratory
p) Warehouse
q) Curing Tanks
r) Washing Area
s) Drivers’ Lounge

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4) SOURCES OF MATERIALS FOR CONCRETE PRODUCTION

The sources of raw materials and other manufactured materials for concrete
production are as follows:

a) Portland Cement (Type 1) – This is manufactured by Southern Province

Cement Co. (SPCC) where cement plant is located in Jizan.
b) Silica Fume – Elkem brand imported from China is being used.
c) Water – Deep well water located at Al-Shati’s batching plant in Baish
d) Fine Aggregates- sourced from Al Shati’s quarry located in Baish
e) Coarse Aggregates – sourced from Hassan Al Hadi, Abu Arish
f) Admixtures (Retarder & Superplasticizer) – Supplied by Fosroc

Test certificates of materials not included in Part 1 are attached per ANNEX
4.

5) TEMPERATURE CONTROL SYSTEM

a) Use of chilled water for batching concrete. The water temperature at the
time of batching should be between 3-7 °C.
b) Replacement of part of batch water with ice.
c) Cooling of aggregates by water spraying of aggregates about 5 hours
before batching concrete. This is achieved by installing water spray
system above the aggregates bin. Relative to this, the aggregates storage
area should be covered with roof.
d) Truck mixers’ rotary drums will be burlapped for insulation purposes while
in transit.
e) Washing with cold water the internal surface of the truck mixer’s rotary
drum prior to loading of fresh concrete.

6) QA/QC IMPLEMENTATION PLAN

Production of good concrete in accordance with RGF’s recommendation stated in

Part 1 of this document and the relevant standards & specifications will be
implemented by the production team as per attached Organization Chart and
QA/QC control checklist (ANNEX 5).

7) PLANT SAFETY & HEALTH POLICIES & PRACTICES

The plant will be equipped with the required safety & health provisions such as
Personal Protective Equipment (PPE), signages, barricades, etc., to ensure that
all the plant activities are conducted in accordance with all safety policies, health
standards, and safe work practices in effect at the plant site.

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8. RISK ASSESSMENT

Severity
Item Impact (Technical, (High,
Risk Item Description of Risk Contingency Plan
No. Schedule,Cost, Quality) Medium,
Low)
1 Electricity Plant shutdown due to lack Delay in project schedule High Continuous power supply thru
of power 2 units of 1000KVA
Generator Sets

2 Water No adequate supply of Delay in project schedule High 1) Supply comes in water
water for batching, trucks from SWCC
washing, etc.
2) Provision of ground water
tanks with a capacity of 500
Cu.M. (2-3 days supply).

3 Raw materials Shortage in the supply of Delay in project schedule High 1) Stock-piling of fine &
(cement & cement, sand , & coarse coarse aggregates on site
aggregates) aggregates and at Baish batching plant
2) Provision of cement silos
(6 silos with capacity of 100-
150tons each).
4 Batching Plant Concrete production Delay in project schedule High 1) One plant on duty, two
Equipment shortage due to Batching plants on request
Plant breakdown
2) Another back-up plant in
Baish
3) Spare parts from Jeddah
(allow 48 hrs for ordering and
available stocking of supply
for worn-out parts).
4) Chiller-maintenance team
on call.
5) Chiller-maintenance
contract with Carrier.
5 Ice for batch Not enough supply of ice Delay in project schedule Medium 1) Storage space for 1,000
water blocks of ice (average 15kg
replacement per block) will be provided.
2) Engage two (2) suppliers
of ice blocks.

PART 3: INDEPENDENT LABORATORY COMPANY PROFILE FOR CONCRETE

Riyadh Geotechnique & Foundations Co. (RGF) was commissioned to do mix designs M1 to M7 and conduct the
corresponding laboratory trial mixes in Abha to be witnessed by representatives from SqWEC (Owner), MHI,
ZACL, Al-Shati Batching Plant. RGF's company profile, including its track record in concrete mix design is
attached herewith as ANNEX 6.

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 ZELAN CONSTRUCTION ARABIA CO. LTD
SHUQAIQ II – IWPP (SITE OFFICE)
Tel. No. (07) 3463731/3463735 Fax. No. (07) 3463040

ANNEX 2

PROPOSED SITE BATCHING PLANT

DETAILED LAYOUT WITH
LOGISTIC ROUTE & LOGISTIC
REQUIREMENT FOR PEAK
CONCRETE CONSUMPTION

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 Doc. No
ZELAN ARABIA CO. LTD
SHUQAIQ II 850MW INDEPENDENT WATER & POWER PLANT
Rev
SAUDI ARABIA
CONRETE SUPPLY QUALITY CONTROL CHECKLIST Date

A) AT BATCHING PLANT:

Location ( Please specify the Chainage or Grid Line Reference )

1) DESIGN STRENGTH AT 28 DAYS = ___________________ 10) OTHER TEMPERATURE CONTROL MEASURES:

2) CEMENT TYPE : ___________________ a) Aggregates sprayed with Water? ___YES ___NO

3) MAXIMUM AGGREGATES SIZE: ___________________ b) Truck Mixer drum "burlapped"? ___YES ___ NO

4) ADMIXTURES USED: ___________________ c) Others:

5) SLUMP AT BATCHING PLANT: ___________________

6) WEIGHT OF ICE ADDED AT PLANT: ___________________

7) CHILLED WATER TEMPERATURE: ____________________

8) AMBIENT AIR TEMPERATURE: ____________________

9) CONCRETE TEMP. AT PLANT: ____________________

B) AT SITE :

QUALITY
TARGET
ACCEPTANCE ACTUAL
Item Description Remarks
CRITERIA VALUE
Yes No

1 Concrete Temperature (per ACI 301) Within 5-35

2 Slump (per ASTM C231) 80 to 180mm (+/- 25mm)

As per project
3 Air Content (per ASTM C231) requirement

OTHERS:
a) Admixture added (if any) = __________________

b) Number of conc. Test cylinders required = _____ Nos.

REMARKS:

CHECKED BY ZACL SUPV / ENG'R INSPECTED BY ZACL QA / QC REP. WITNESSED BY MHI REP

SIGNATURE

NAME

DATE

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 ZELAN CONSTRUCTION ARABIA CO. LTD
SHUQAIQ II – IWPP (SITE OFFICE)
Tel. No. (07) 3463731/3463735 Fax. No. (07) 3463040

PART 3
INDEPENDENT LABORATORY
COMPANY PROFILE FOR
CONCRETE

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