to hq 02 042 00 philosophy civil works onshore

OMV Exploration & Production GmbH

00 Final Issue AF 31/05/05 JEA 31/05/05 PZ 03/06/05 MF 03/06/05

A2 Client Comments Incorporated AF 26/04/05 GMacD 26/04/05

A1 Issued for Comment/Approval AF 15/12/04 AS 17/12/04

Issue Rev

Issue or Revision Description Origin By

Date Chkd By

Date Appd By

Date Auth By

Date

Philosophy for

Civil Works Onshore

Document Number

TO-HQ-02-042-00


Document Number Rev Page Philosophy for Civil Works

Onshore TO-HQ-02-042 00 2 of 32

Revision History

Revision Description of revision A1 Issued for Comment / Approval

A2 Comments Incorporated

00 Final Issue




Contents

1.0 PREFACE .......................................................................................................................5

2.0 DEFINITIONS .................................................................................................................5

3.0 ABBREVIATIONS...........................................................................................................5

4.0 INTRODUCTION.............................................................................................................5

5.0 APPLICABLE CODES, STANDARDS AND REGULATIONS........................................6 5.1 Codes and Standards List ........................................................................................................ 6

6.0 DESIGN GUIDELINES....................................................................................................7 6.1 Design Loads ............................................................................................................................. 7 6.2 Load Combinations ................................................................................................................. 10 6.3 Miscellaneous Loads............................................................................................................... 11 6.4 Permissible Stresses............................................................................................................... 11 6.5 Stability (Pad Type Foundations) ........................................................................................... 11 6.6 Grouting.................................................................................................................................... 12 6.7 Baseplate Levels...................................................................................................................... 12 6.8 Reinforced Concrete Foundations and Structures............................................................... 12 6.9 Design Methods ....................................................................................................................... 12 6.10 Machinery Foundations .......................................................................................................... 13 6.11 Concrete ................................................................................................................................... 14 6.12 Reinforcing Steel ..................................................................................................................... 14 6.13 Design and Construction of Roads........................................................................................ 14

7.0 CONSTRUCTION .........................................................................................................17 7.1 General ..................................................................................................................................... 17 7.2 Materials ................................................................................................................................... 18 7.3 Concrete Mix Design, Proportioning and Mixing.................................................................. 20 7.4 Concrete Transport and Placing ............................................................................................ 24 7.4 Formwork and Finish .............................................................................................................. 28 7.5 Reinforcement.......................................................................................................................... 30

8.0 DOCUMENTATION REQUIREMENTS.........................................................................31




9.0 CERTIFYING AUTHORITY REVIEW REQUIREMENTS..............................................32




1.0 PREFACE

This Philosophy defines the OMV Exploration & Production GmbH corporate policy on the design of Civil Works for onshore hydrocarbon production and processing facilities. The document specifies basic requirements and criteria, defines the appropriate codes and standards, and assists in the standardisation of facilities design across all onshore operations.

The design process needs to consider project specific factors such as the location, production composition, production rates and pressures, the process selected and the size of the plant. This philosophy aims to address a wide range of the above variables, however it is recognised that not all circumstances can be covered. In situations where project specific considerations may justify deviation from this philosophy, a document supporting the request for deviation shall be submitted to OMV E&P for approval.

Reference should be made to the parent of this philosophy, document number TO-HQ-02-001 for information on deviation procedures and Technical Authorities, general requirements and definitions and abbreviations not specific to this document.

2.0 DEFINITIONS

There are no definitions with particular relevance to this document.

3.0 ABBREVIATIONS

The following abbreviation is relevant to this document.

RC Reinforced Concrete

4.0 INTRODUCTION

This philosophy defines the loads and design criteria to be taken into account in the design of general civil works for onshore oil and gas production plants (facilities) and their associated pipelines and roads. These loads shall be utilised irrespective of the material employed in the construction of the various structures.




5.0 APPLICABLE CODES, STANDARDS AND REGULATIONS

Codes, standards and regulations referred to in this philosophy shall be of the latest edition and shall be applied in the following order of precedence: -

Local Regulations, The provision of this document, International standards (e.g. ISO, IEC etc), National standards.

Design of the Civil Works shall comply with the standards listed within this philosophy, however, for instances where local standards are more onerous local standards shall apply.

5.1 Codes and Standards List

BS 12 Ordinary and rapid hardening Portland cement. BS 1881 Methods of testing concrete

BS 8500 Complimentary standard for BS EN 206

BS 8666 Spec for bending and cutting of steel reinforcement for conc.

BS 4027 Sulphate resisting Portland cement BS 4246 Low heat Portland blast furnace cement BS 4449 Hot rolled steel bars for reinforcement of concrete BS 4482 Specification for cold reduced steel wire BS 4483 Steel fabric for the reinforcement of concrete BS 4550 Methods of testing cement BS 6399 Code of practice for dead, imposed, and wind loads BS 8000 Workmanship on building sites BS 8004 Foundations BS 8007 Concrete for liquid retaining structures BS 8110 The structural use of concrete BS CP 2012 Foundations for machinery




BS EN 12620 Aggregates for concrete BS EN 13139 Aggregates for mortar BS EN 196 Methods of testing cement BS EN 206 Concrete spec, performance, conformity BS EN 480 Concrete admixtures

BS EN 932 Tests for general properties of aggregates BS EN 1008 Mixing water for concrete, specification for sampling BS EN 1097 Tests for mechanical and physical properties of

aggregates BS EN 1097 Tests for mechanical and physical properties of

aggregates BS EN ISO 4066 Construction drawings, bar scheduling

6.0 DESIGN GUIDELINES

6.1 Design Loads A site soil investigation should be undertaken by an approved geotechnical engineer prior to commencement of design. This is required to both establish civil engineering design parameters and to enable an accurate cost estimate to be produced.

The minimum loading design basis shall be as specified in the referenced codes and specifications except as amended herein. Local codes and regulations shall govern when they are more stringent In addition to the dead loads, foundations and structures shall be designed for the following external loads and forces:

Live Loads Maintenance Loads Wind Loads Snow and Ice Loads Thermal Loads Vibration Loads Equipment Loads




Impact Loads Test Loads t Fluid Surge Loads Blast Loads Seismic Loads Transportation Loads (If applicable) Lifting Loads (If applicable)

6.1.1 Live Loads

Live loads shall be the imposed load on a structure, floor, platform, walkway or stair due to operation or maintenance. Allowance for dynamic effects, including impact, shall be made for loads arising from machinery, runways, cranes and other plant producing periodic disturbing forces. Live loads for general civil works shall be in accordance with the appropriate code, but not less than the following, and actual equipment loads shall be used if heavier. Imposed Load in General Areas 5.0 kN/m2

Imposed Load in Plant Areas 7.5 kN/m2

6.1.2 Maintenance Loads

The minimum live loads specified above should be reviewed for their adequacy in areas that may be subjected to heavy equipment and material loads during periodic maintenance operations. Heat exchanger support structures shall be designed for the tube bundle pushing and pulling forces along the longitudinal axis of the heat exchanger. These forces shall be based on the type of fluid on the shell side of the exchanger. For crude residue, cracked tar, hydrogen fluoride and similar service, 150 percent of the weight of the tube bundle shall be used; for distilled oil, vapour, clean water and steam, 100 percent shall be used.




6.1.3 Wind Loads

Wind loads shall be calculated in accordance with the local national standard or codes, using the basic wind speed appropriate to the site. It may be assumed that the wind loading during erection, assembly, test conditions and full hydrostatic test does not exceed 60% of the design wind load.

6.1.4 Snow and Ice Loads

Basic snow loading shall be considered as 0.8 kN/m2 in areas where this is a real consideration.

6.1.5 Thermal Loads

Thermal load shall be the load acting on a structure due to change in temperature of machinery or process equipment. The longitudinal thermal and friction loads on a pipeway shall be taken as 10% of the total operating pipe load or 30% of any one or more lines known to act simultaneously in the same direction, whichever is the greater. The horizontal force from expansion/contraction acting on members supporting exchangers and horizontal vessels shall be taken as equal to either the friction force or the force required to produce the expansion or contraction. Friction expansion forces shall be the greater of the empty or operating weight times the friction co-efficient taken from the following table: - Surfaces Friction FactorSteel-to-Steel 0.3 Teflon-to-Teflon 0.1 Lubricated rollers on steel bearing plates 0.05




6.1.6 Vibration Loads

Where vibration induced by equipment or operation is specified or anticipated, supporting members and foundations shall be designed to prevent fatigue failure and to avoid misalignment or malfunction of machinery and equipment. The natural frequency of a member of a structure, which supports equipment subject to vibration, shall be outside the range of 0.70 to 1.40 times the exciting frequency.

6.1.7 Impact Loads

Impact loads resulting from dropped objects or lifting aids shall be considered in the design of the civil works.

6.1.8 Test Loads

Test loads shall include all loads and load combinations that occur during testing of piping, vessels, equipment and structures.

6.1.9 Fluid Surge

Forces resulting from the surging action of liquids or fluidised solids in process equipment or piping shall be considered in the design of the supports.

6.1.10 Construction Loads

In addition to the loads imposed upon the structure in its installed condition, all parts of the structure and any temporary works shall be designed to accept the loads imposed on them during all conditions of transportation, construction and erection. Extreme point loads can be introduced during lifting operations.

6.2 Load Combinations Combination of loads and forces shall be considered for the design of all structures, foundations and stability against overturning using allowable design stresses as specified in the appropriate design codes except where indicated otherwise in these specifications.




6.3 Miscellaneous Loads Pipe Anchors

Pipe anchors shall be designed for the forces developed under any conditions. The design of supports anchoring more than one line shall accommodate the most stringent combination of forces due to abnormal conditions on the following basis: -

Total No. of lines at an anchor support that could have abnormal conditions

Percent of lines under abnormal conditions to be used in design

1 2 4

Over 4

100% 50% 25%

6.4 Permissible Stresses Basic allowable stresses for concrete, piling and soil pressures may be increased by the amounts shown below for load combinations which include wind or test loading providing the basic allowable stresses are not exceeded for combinations excluding these loads.

Load Stress Increase Wind 25% Test 20% Load Combination Stress Increase Test Load + 50% Wind 25%

No stress increases shall be allowed where wind is the dominant loading, e.g. stacks, towers, tall columns.

6.5 Stability (Pad Type Foundations) Stability Ratio = Stabilising Moment Overturning Moment The minimum stability ratios shall be as follows:-




Erection condition: For dead load for a support for a vessel or structure, acting with or without wind, the stability ratio shall be a minimum of 1.5. All other design conditions: For dead and live loads for a support acting with or without wind, the stability ratio shall be a minimum of 1.8.

6.6 Grouting The minimum thickness of grout shall be 25 mm unless otherwise specified by equipment or machinery manufacturers.

6.7 Baseplate Levels The underside levels of equipment and stanchion bases shall be 300mm above high point of paving unless otherwise stated.

6.8 Reinforced Concrete Foundations and Structures Refer to the Geotechnical Site Investigation Report and Structural Building Specification or equivalent guidance document for foundation and pile design criteria.

6.9 Design Methods Analysis of concrete structures shall be performed according to the design methods contained in the appropriate code.

6.9.1 Spread Foundations

Foundations for minor pipe supports and small items of equipment may be supported on paving or spread footings provided the soil bearing pressure does not exceed the permissible bearing pressure, and that the resulting differential settlement is allowed for.

6.9.2 Sliding

The safety factor against sliding shall be taken as 2.0 and in complying with the requirements it shall be necessary to ascertain that the resulting pressures and shear forces to be transferred from the foundations to the supporting soil shall not be greater than the permissible.

6.9.3 Uplift

The minimum safety factor against uplift of foundations shall be 1.5




6.10 Machinery Foundations Foundation Ratio

The minimum ratio of weight of concrete to weight of machines for minor equipment items i.e. pumps etc, shall be: - Centrifugal machines ratio 3:1 Reciprocating machines ratio 4:1 Machine manufacturers requirements

6.10.1 Analysis

Where appropriate vibration analysis for vibrating equipment shall be carried out. The pile stiffness, i.e. horizontal and vertical, used in the analysis shall be based upon the results from the in-situ dynamic pile tests, such tests being executed on piles having the same characteristics as those supporting the foundations. The exciting forces used shall be the maximum values and shall be defined as either: -

The manufacturers recommended values occurring during the lifetime of the equipment.

The values as computed from the relevant Codes of Practice

mentioned above.

6.10.2 Allowable Amplitudes

The allowable amplitudes shall not exceed the lower of the following values: -

The maximum allowed by the manufacturer of the equipment The amplitude of the vibration of the foundations for rotary and

reciprocating machines shall not exceed the limit as defined in the relevant Codes of Practice.

The amplitude in rotating machines which causes the effective velocity of vibration to exceed 2mm/sec.




6.10.3 Static Deformations

The static deformations of the foundations for rotary equipment shall be within the limits defined by the machine manufacturer. Where applicable, the effects of deformations caused by the following shall be investigated: - Shrinkage and creep of concrete. Temperature effects caused by radiation or convection of heat or cold generated by machinery, piping and ducting.

6.11 Concrete The grade of concrete used in the works shall be in accordance with BS 8110 and shall be designated as follows:-

Grade C40 Foundations, pile caps, floor slabs, walls and RC structures

Grade C30 Area paving, cable trenches and minor miscellaneous flooring

Grade C15 Blinding

6.12 Reinforcing Steel Hot rolled, high yield, high bond bars shall be used for main steel (460N/mm2 yield stress) For links, stirrups, binders and support chairs, mild steel shall be used (275N/mm2 yield stress)

6.13 Design and Construction of Roads 6.13.1 General

In general all roads and pavements shall be in accordance with the relevant Department of Transport design criteria. Detailed information can be found on the website www.official-documents.co.uk /document/deps/ha/dmrb/index.htm

A site soil investigation should be undertaken by an approved geotechnical engineer at sensible intervals throughout the length of the proposed road prior to commencement of design. This is required to both establish civil engineering design parameters and to enable an accurate cost estimate to be produced.




An Environmental Impact Assessment (EIA) should be carried out in accordance with local environmental legislation, in advance of any construction works. Where local legislation does not exist an EIA should be undertaken in accordance with the Design Manual for Roads and Bridges: Volume 11

The site investigation and EIA should be considered together taking account of holistic factors including the need for drainage culverts, fords, bridges and the use of geotextiles.

6.13.2 Sub-Grade Assessment The sub-grade is normally not strong enough to carry the construction traffic without distress, unless it is rock which is not subject to degradation by weathering. Therefore, unbound or bound foundation layers of adequate stiffness modulus are required to reduce the stresses on the sub-grade. Unbound aggregates and soils can suffer from permanent internal deformation when subjected to high stresses. They tend to have relatively poorer permanent deformation characteristics and lower shear strength than bound materials. There is no established test to predict susceptibility of these materials to permanent deformation. It is common for the Engineer to infer from materials and index tests that materials have an acceptable level of stiffness modulus and shear strength. Both stiffness modulus and shear strength are usually reduced by increases in moisture content. Volume 7, Section 2, Part 1 from the above noted website, or similar guidance document, should be used to assist with sub-grade assessment.

6.13.3 Sub-Base Granular and cemented sub-bases are permitted for flexible and flexible composite pavements but only cemented sub-bases are permitted for rigid and rigid composite pavements. The grading for unbound granular sub-base is intended to provide a dense layer of relatively high stiffness modulus, which is reasonably impermeable and will thus shed rain water during construction, given adequate fall. It is not necessarily free draining and may exhibit suction, and thus increase in moisture content. Granular sub-base with a laboratory CBR of at least 30% should provide an adequate platform for construction of the pavement when compacted to the appropriate thickness. It is of vital importance to keep water out of the sub-base and sub-grade, both during construction and during the service life of the road. This is achieved by excluding incoming water and providing an escape route for water already in the




foundation. During construction, every effort should be made to protect the sub-grade by placing aggregate before rain can soften it. Wherever possible the foundation drainage should be kept separate from pavement run-off drainage in all new construction work. There should always be a downslope route from the sub-base to the drain. Foundation layer testing should be undertaken periodically to check compliance with the design during construction. Both in-situ and laboratory tests should be carried out as a means of cross checking. Tests should generally be undertaken in accordance with BS 1377 or equivalent code of practice. Volume 7, Section 2, Part 1 from the above noted website, or similar guidance document, should be used to assist with sub-grade assessment.

6.13.4 Surfacing General As a minimum standard all roads shall be designed for a 100 Tonne fully loaded HGV. All roads shall have a minimum bend radius of 15m. Height of road construction above the water table and/or likely flood levels should be considered within the design. This may vary from +0m in desert regions to +5m where seasonal flooding can be expected. The gradient of side slopes leading away from the edge of the road shall take into consideration drainage and slope stability requirements. Safety measures should be included where the length or steepness of these slopes are deemed excessive. Passing lanes and/or traffic management systems should be considered as part of the road design.

Drilling Roads Drilling roads should be constructed to a minimum width of 4m although widths of up to 6m may be considered depending on volume of traffic and likely operational life of the road. Unless adverse ground conditions dictate otherwise the road construction shall comprise granular fill compacted in layers as a minimum standard. Exact material specifications and construction methods shall be in accordance with the Specification for Highway Works or similar equivalent document.

Production Roads Production roads should be constructed to a width of 4m. Unless adverse ground conditions dictate otherwise the road construction shall comprise granular




fill compacted in layers as a minimum standard. Exact material specifications and construction methods shall be in accordance with the Specification for Highway Works or similar equivalent document.

Facility Roads Facility roads should be constructed to a width of 5-6m depending on specific requirements. Unless adverse ground conditions dictate otherwise the road construction shall comprise of granular fill sub-base compacted in layers with either an asphalt base course / wearing course or concrete pavement surfacing. Exact material specifications and construction methods shall be in accordance with the Specification for Highway Works or similar equivalent document. Bridges Any bridges that may be needed as part of the required road/infrastructure shall be designed to the requirements of BS 5400 or similar equivalent code of practice.

7.0 CONSTRUCTION

7.1 General This section covers the construction of concrete structures, foundations and paving. The work shall be carried out in accordance with the requirements of the relevant standards and the local building byelaws, to the satisfaction of the Engineer and the Local Authority. In many countries where OMV E&P GmBH operate, there may not be national guidelines or authorities. Work undertaken in these circumstances shall use the provisions of this document and all related standards in order to obtain a minimum benchmark of engineering and construction. The Contractor shall provide all labour, supervision, tools, materials and equipment, and shall perform all operations necessary to complete the work in accordance with the contract drawings and appropriate specifications.




7.2 Materials

7.2.1 Cement

The type of cement to be used will be as specified on the drawings. All cement shall be certified by the manufacturer as complying with the appropriate specification. The Contractor shall supply the Engineer with the Manufacturers test certificate for each batch of cement delivered to site. Cement, which has been in storage on site for 3 months or over, shall be tested to prove that its quality is still in accordance with the specification. Cement shall be tested in accordance with the appropriate standards, to the Engineers satisfaction. Samples shall be taken from deliveries as directed by the Engineer.

7.2.2 Aggregates

Sand, fine and coarse aggregate shall comply with the appropriate standard. Aggregates shall be stored in such a manner to prevent mixture of the materials and contamination. The Engineer shall approve the source of the aggregate supply. The Contractor shall supply full geological and physical characteristics, details and samples of the materials proposed for use within the works, for approval by the Engineer. All designated aggregate material, including test and inspection requirements and frequencies, shall be in accordance with the Specification for Highway Works or an equivalent document.

7.2.3 Formwork

Shuttering shall be made of timber, metal or precast concrete. The moulds shall be, in every respect, adapted to the structure and to the required surface finish of the concrete. If made of timber, the moulds shall be made of sound and properly seasoned wood, free from loose knots. Wedges and clamps shall be used whenever practicable instead of nails. The use of plugs, bolts, wire, ties, holdfasts and any other appliances for supporting the formwork shall be kept to a minimum.




Mould coating shall be oil or other suitable approved material of such a nature that it shall not stain the concrete or injure it by chemical action nor be absorbed by the timber. It is to be slow drying and not liable to congeal nor be affected by rain or the water used for cleaning the shutters. It shall be insoluble in water and not adversely affected by climatic conditions or temperature.

7.2.4 Water

The water used in concrete shall be clean and free from injurious quantities of oil, acid, alkali, organic or other deleterious substances. Water used in concrete shall be tested in accordance with the appropriate standard if deemed necessary by the Engineer. Water as described in the following clauses will not be used for mixing: Sea water Other water containing more than 4750 parts per million total dissolved solids, more than 500 parts per million total sulphates, more than 1000 parts per million chlorides or more than a trace of hydrogen sulphide.

7.2.5 Reinforcement

All reinforcement bars shall be one of the three types listed below:

Mild steel hot rolled plain round bar in accordance with the appropriate standard with a minimum specified characteristic strength of 250N/mm2

High yield hot rolled deformed bar in accordance with the appropriate standard with a minimum specified characteristic strength of 460N/mm2

Mesh fabric in accordance with the appropriate standard Binding wire shall be black annealed mild steel wire 14swg The Contractor shall furnish the Engineer with copies of Manufacturers test certificates for any reinforcement to be supplied. Reinforcement shall be stored on site in racks or on supports that will keep it off the ground in such a manner as to provide easy identification of separate bars, to avoid distortion and to prevent contamination and corrosion.




7.2.6 Grout

Grout for filling under base plates or towers, vessels, structural columns, machinery, etc. shall be one of the types given below, and shall be specified on the drawings: For general use Portland cement and sand in volumetric proportions 1:2. For bolt sleeves, shear pockets and under base plates of heavy equipment machinery, compressors etc a high strength, non-shrink grout, mixed and applied strictly in accordance with the Manufacturers instructions.

7.2.7 Additives for Concrete

No additives or admixtures shall be used without written approval of the Engineer.

7.3 Concrete Mix Design, Proportioning and Mixing

7.3.1 Concrete Quality

Unless shown otherwise on the drawings, minimum grades of concrete to be used in the works shall be as follows: Foundations, equipment supports, superstructures, buildings, retaining wall and pits Grade C35 Paving Grade C30 Fireproofing to structural steelwork Grade C20 Mass concrete and blinding Grade C15

7.3.2 Mix Design

The designed mix for each grade of concrete used in the works shall be in accordance with BS 8500 or equivalent national (or international) standard.




The minimum cement content and maximum free water-cement ration shall be in accordance with the following table. Grade Nominal

Max Aggregate Size

Minimum Cement Content

Kg/m3

Max Free Water / Cement Ratio

Designed Cube Strength @ 28 Days N/mm2

(Characteristic Compressive Strength)

Uses

C40 20mm 325 0.55 40 Foundations & Structures

C40 10mm 365 0.55 40 Control Buildings, External Walls

C35 10mm 340 0.60 35 Topping to Pre-cast Floors

C30 20mm 300 0.60 30 Paving

C20 14mm 300 0.50 20 Fireproofing to steelwork

C15 40mm 300 0.5 15 Mass Concrete

C15 20mm 300 0.5 15 Blinding

7.3.3 Preliminary Trial Mixes

At least three weeks before commencement of any concrete work, the Contractor shall submit to the Engineer full details of the mix proposed for each grade of concrete and shall have already completed trial mixes and all tests for each of these using sample aggregates and cements typical of those to be used. Preliminary tests shall be made from the proposed mixes as follows: For each grade, a trial mix using the proposed proportions shall be made on each of three different days. One slump test and six cubes shall be carried out for each trial mix. From each batch of six cubes compression tests shall be carried out on three cubes at seven days and the remaining three cubes at 28 days. The cubes shall be made, cured, stored, transported and tested in accordance with the appropriate codes and standards.




7.3.4 Workability

Concrete shall be of such consistency that it can be readily worked into corners and angles of the formwork, and around reinforcement so that there is no segregation of materials or bleeding of free water to the surface. Slump tests shall be used as a guide to workability.

7.3.5 Acceptance Criteria for Works Cube Tests

Acceptance criteria for all tests shall be in accordance with the appropriate codes and standards.

7.3.6 Under Strength Concrete

Where concrete does not comply with the acceptance criteria, and where directed by the Engineer, cylinder core specimens shall be cut from the hardened concrete in the works for the purpose of examination and testing. The Engineer shall approve the cutting equipment and the method of executing the work. The specimens shall be cut and tested for compressive strength in accordance with the appropriate codes and standards. Where the equivalent cube strength of the specimens is less than the appropriate specified minimum cube strength at 28 days, the concrete structure or part of it shall be removed and replaced to the Engineers satisfaction.

7.3.7 Defective Concrete

Rendering of defective concrete, as a means of making good will not be permitted except that, in the case of minor porosity on the surface, the Engineer may approve a surface treatment by rubbing down with a cement mortar of the same fine aggregate/cement ratio as the concrete. This treatment shall be made immediately after removing the formwork. Concrete containing honeycombing, major air holes or similar defects will be cut out and replaced as directed by the Engineer. Surface preparation shall include chipping and brushing to remove the weaker upper layers of concrete, damaged concrete and any oil soaked areas before final thorough cleaning. No repair shall be executed without the Engineers approval.




7.3.8 Changes in Material and Mix Proportions

Neither the mix proportions nor the source of supply of materials shall be altered without the prior approval of the Engineer.

7.3.9 Mixing

All concrete shall be mixed in a batch mixer of approved design and in accordance with the appropriate codes and standards. The mixer shall be fitted with the Manufacturers plate stating the rated capacity and the recommended revolutions per minute. Batching of cement with aggregates shall be by weight, and a separate weighing device shall be provided for weighing the cement. Water shall be measured by volume or weighed but in either case the delivery shall be easily adjustable to deliver a pre-determined amount to ensure a constant water / cement ratio. Allowance shall be made for the free water content in the aggregates, which shall be checked daily, after every delivery of aggregate, or as instructed by the Engineer. The Contractor shall make periodic checks to confirm the accuracy of the weighing equipment.

7.3.10 Records

The Contractor shall keep records of the location in the works of all batches of concrete, their grade and all test cubes or other tests taken from them, together with the date and time of the pour. These records shall be available for inspection by the Engineer.

7.3.11 Ready Mixed Concrete

Ready mixed concrete shall only be used when the Engineers approval has been obtained in writing. Ready mixed concrete shall conform to the preceding requirements except as modified hereunder. The supply and delivery of ready mixed concrete shall comply with the appropriate codes and standards. The ready mixed concrete suppliers shall supply a guarantee of the required concrete strength; a copy of the grades of materials used and test certificates of preliminary strength tests. Samples of aggregate shall be obtained as directed by the Engineer or his representative, and submitted to an approved laboratory for testing.




The ready mixed concrete plant will be inspected regularly by the Engineer or his representative, for cleanliness and ability to supply concrete as specified.

7.4 Concrete Transport and Placing 7.4.1 Transport

Concrete shall be conveyed from the mixer to its location as rapidly as possible by methods approved by the Engineer, which will not cause segregation, adulteration, loss of ingredients, or contamination. The Contractor shall ensure that all concrete is at the required workability at the time of placement.

7.4.2 Placing

The concrete shall be placed before setting has commenced and shall not be subsequently disturbed. The concrete shall be placed in positions and sequences indicated on the drawings, in the specification or as directed by the Engineer. Except where otherwise directed, concrete shall not be placed unless the Engineer is present and has previously examined and approved the positioning, fixing and conditioning of the reinforcement and of any other items to be embedded, and the cleanliness, alignment and suitability of the containing surfaces. Special care shall be taken to ensure that formwork is free of standing water. The concrete shall be deposited in its final position, working from the stop end, if any. It shall be placed in such a manner as to avoid segregation of the concrete and displacement of the reinforcement, other embedded items or formwork. It shall be brought up in horizontal layers not exceeding 450mm in compacted thickness unless otherwise authorised or directed by the Engineer. Placing shall be continuous between specified or approved construction joints. Concrete shall not be allowed to fall freely more than 2.0 metres. Where the Contractor decides to pump the concrete, the Engineer shall approve the type of pump used. Any adjustment that may be required to be carried out shall first be approved in writing by the Engineer.




7.4.3 Compaction

The concrete shall be fully compacted throughout the full extent of the layer. It shall be thoroughly worked against the formwork and around any reinforcement and other embedded items, without displacing them. Successive layers of the same lift shall be thoroughly worked together.

7.4.4 Mechanical Compaction

All concrete will be mechanically compacted unless the Engineer issues other instructions in writing. Mechanical vibrators, consisting of (a) external shutter, (b) internal poker and (c) mechanical tamping or screeding types shall be used solely to compact concrete when it has been placed in its final position. Care shall be exercised when using mechanical vibrating apparatus to avoid segregation of the aggregate. The poker shall be inserted around the edges of the work as close to the shuttering as possible without touching it. Prolonged insertion of this type of vibrator or its use on wet mix is forbidden. External vibrators shall be securely clamped to the studding of the formwork and should be maintained at a constant depth of 450mm below the surface of the deposited concrete. Care should be exercised to prevent the appearance of laitance due to over vibration. Surface or Pan type vibrators shall be employed in the compaction of floors, slabs etc. and the whole area cast should be uniformly traversed in order that a homogeneous surface texture should be obtained without the appearance of laitance. Immersion vibrators shall penetrate the full depth of the concrete layer and, where the lower layer is freshly placed, the vibrator shall re-vibrate the upper section of that layer to ensure a full mix between the concrete layers.

7.4.5 Construction Joints

Concreting shall be carried out continuously up to construction joints, the position and arrangement of which shall be as indicated on drawings or as approved by the Engineer.




The shuttering for a construction joint shall be prepared and ready at the commencement of the days concreting. The shuttering for joints through which reinforcement passes shall be so devised as to prevent undue leakage of cement or concrete. After striking shuttering at the joint, any concrete that has flowed past the stop shall be removed. The face of the concrete shall be well hacked and all laitance and loose material shall be removed. Immediately prior to resumption of concreting the face of the joint shall be soaked with water and covered with a thin layer of freshly made sand/cement mortar (1:1 mix).

7.4.6 Curing and Protection

Curing shall comply with the appropriate codes and standards. Concrete shall be protected during the first stage of hardening from the harmful effects of sunshine, drying winds, cold, rain, or running water. The protection shall be applied as soon as practicable after completion of placing by one or more of the following methods. The concrete shall be covered by a layer of canvas, hessian or similar absorbent material, or a layer of sand, kept constantly wet for 7 days. Except in the case of surfaces to which concrete has subsequently to be bonded, the concrete shall be cured by application of an approved liquid curing membrane. The Contractor shall use extreme caution to ensure that the liquid curing membrane is applied uniformly and in sufficient quantity to provide a waterproof coating. Application shall be made by low-pressure spray strictly in accordance with the manufacturers instruction. On horizontal surfaces, the curing membrane shall be applied immediately after placing the concrete, and on vertical surfaces immediately after removing the formwork.

7.4.7 Grout Application

The minimum thickness of grout shall be 25mm except where noted otherwise on the drawings. The quality and type of grout shall be in accordance with the drawings, or as directed by the Engineer. Grout shall be applied as thick as possible consistent with fluidity. It shall be poured under a suitable head and tamped until the space is completely filled. The grout shall fill all voids between the base or sole plate and the foundation and shall have full surface contact.




Grouting shall accord with the following parameters for placing: All structural steelwork supporting equipment, piping etc. shall be grouted in position after alignment and plumbing of such structures allowing for necessary tolerances both in a vertical and horizontal face, and before the erection of equipment etc upon the structure. All equipment etc. not supported by steelwork but directly supported by concrete shall have sufficient steel shims with waxed surface for easy removal to distribute the equipment load in such a manner as to ensure the concrete is not over stressed before application of grout. Grout shall be kept moist during the first 2 days after placing and be protected from sunshine and drying out by protective covering. Care shall be taken that all wedges, shims and other packings shall be removed beneath machinery only after grout has achieved adequate strength and the shim recesses shall be filled with grout of the same quality. When jackscrews are used in lieu of wedges, adequately sized steel plates shall be used in order to distribute the load to the foundations.

7.4.8 Concrete Floors (Ground Slabs)

Floor slabs shall be concreted in alternate panels not greater than 6m x 6m. Floor slabs shall be separated from adjoining foundations by 12mm thick Flexcell or equal joints. Expansion joints between floor slabs and foundations shall be 25mm thick type Flexcell or approved equal. Floor slabs are to be compacted as previously specified and shall receive a surface finish as stated on construction drawings.

7.4.9 Paving

Where required, paving will consist of 4.5% air entrained concrete of minimum grade 30. The concrete shall be reinforced with either (a) Fibremesh which shall be added in accordance with the Manufacturers instructions, or (b) one or two layers of steel reinforcement bars. The minimum laps to mesh reinforcement shall be 300mm. The Contractor shall submit his concreting proposals for bay sizes and construction joints to the Engineer for approval. The concrete surface finish shall be directed by the Engineer.




7.4 Formwork and Finish 7.5.1 General

Formwork will comply with the appropriate codes and standards. All shuttering shall be substantially and rigidly constructed and shall be in every respect adapted to the structure. It shall be fixed to true lines and levels and efficiently propped and braced to prevent deformation, displacement, deflection or movement of any kind due to the weight of the construction of adjacent works or the deposition of the concrete. All joints shall be tight enough to prevent the leakage of liquid and cement grout, particularly when the concrete is being vibrated. The shuttering shall be constructed in such a manner as to facilitate easing and removal in the correct sequence without damage to the concrete. Shuttering for beams and similar structures shall be so constructed that the sides may be struck without endangering the bottom boards and supports. Where necessary to maintain the specified tolerances the formwork shall be cambered to compensate for any anticipated deflections in the formwork due to the weight and pressure of the fresh concrete and due to the construction loads. Where beams and slabs are likely to present a noticeable deflection due to dead weight, they shall be precambered by arranging the shuttering to give as near as possible a circular curve, equal to the deflection expected on the beam or slab. Prior to commencement of concreting, all formwork shall be carefully examined and the inside of all forms completely cleaned out, openings being left as necessary for this purpose. Before concreting, the inside of all shuttering shall be coated to prevent adhesion, particular care being taken to ensure that the coating substance shall not contaminate the reinforcement.

7.5.2 Formed Surfaces Classes of Finish

Class F.1 This finish is for surfaces against which backfill or further concrete will be placed. Formwork shall be of sawn boards, sheet metal or any other suitable material, which will prevent loss of grout when the concrete is vibrated. Concrete shall not be poured directly against an excavated face but only against suitable formwork as defined above, except as otherwise directed by the Engineer.




Class F.2 This finish is for surfaces permanently exposed to view. Formwork shall be faced with wrought and thickness boards with square edges arranged in uniform pattern. Alternatively plywood or metal panels may be used if they are free from defects likely to detract from the general appearance of the finished surface. Joints between boards and panels shall be horizontal and vertical unless otherwise directed. The finish shall be such as to require no filling of surface pitting. Butt fins, surface discolouration and other minor effects shall be remedied by approved methods.

7.5.3 Unformed Surfaces Classes of Finish

Class U.1 Rough Finish This is a screeded finish for the surface of foundations, beds, slabs and structural members to be covered by backfill, subsequent stages of construction, bonded concrete topping or cement mortar beds to receive pavings. The finishing operations shall consist of levelling and screeding the concrete to produce a uniform, plain or rigid surface, surface concrete being struck off by a straight edge immediately after compaction. Class U.2 Floated Finish After the concrete has been placed, struck off, consolidated and levelled, the concrete shall not be worked further until ready for floating. Excess water shall be removed from the surface by blotting or a loop of hose, not by sprinkling dry cement on the surface. Floating shall begin when the water sheen has disappeared and/or when the mix has stiffened sufficiently to permit the proper use of wooden, cork, or power-driven floats. If power-driven floats are used, they shall be of the impact-type except in thin sections such as pan slabs. Trueness of surface shall be rechecked at this stage with a 3.0 metre straight edge applied at not less than two different angles. All high spots shall be cut down and all low spots filled during this procedure to produce planes checking true under the straight edge in any direction, with tolerances not exceeding 3mm in 3.0 metres. The slab shall then be refloated immediately to a uniform, smooth, granular texture.




Class U.3 Trowelled Finish Where a trowelled finish is specified, the surface shall be worked first as specified above for floated finish, then with either power trowels or hand trowels. The first trowelling after floating shall produce a smooth surface, which is relatively free from, defects but which may still contain some trowel marks. Additional hand trowelling shall be done after the surface has hardened sufficiently. The final trowelling shall be done when a ringing sound is produced as the trowel is moved over the surface. The surface shall be thoroughly consolidated by the trowelling operations. The finished surface shall be free of trowel marks and shall be uniform in texture and appearance. On surfaces intended to support floor coverings, any defects of sufficient magnitude to show through the floor covering shall be removed by grinding.

7.5 Reinforcement All reinforcement must be free from oil, grease, loose rust mill scale or other harmful matter immediately before placing concrete. All bending shall be done cold with a suitable bar bending machine in accordance with the appropriate code, to the shape shown on the drawings and/or bending schedules. Re-bending of incorrectly formed bars will not be permitted. Bars must be of the required lengths and lapping or welding of main bars shall not be permitted except as indicated on the construction drawings or unless permission is received from the Engineer to do so. Where delay occurs between the assembling of the steel and the placing of the concrete, the reinforcement shall be checked prior to concreting. If reinforcement has been exposed for a considerable time prior to concreting being carried out, bars shall be wire brushed to remove loose rust or other deposits. Any material brushed off which falls into the shuttering shall be cleared when the shuttering is cleaned out. The number, size and position of all bars shall be in exact accordance with the approved drawings. The intersection of all bars shall be bound with 14 s.w.g. soft annealed iron wire or approved spring steel wire clips, to prevent displacement before and during the placement of the concrete. Concrete distance blocks unless otherwise directed shall be used between the reinforcement and the bottom and sides of the forms to ensure correct cover over the bars.




The reinforcement will be constructed such that sufficient support is provided to ensure that there is no sagging of the members during any stage of the construction. No form of ties or tying methods, which are likely to cause spalling of concrete during form stripping or discolouration of concrete surfaces, shall be used. Connections external to the finished surface shall only be used on approval of the Engineer. Cover The following minimum concrete cover to steel reinforcement shall be adhered to unless otherwise shown on the drawings:

Concrete cast directly against earth 75mm Buried concrete, exposed to water or weather 50mm Not exposed to weather 25mm Not in contact with earth or water 25mm

8.0 DOCUMENTATION REQUIREMENTS

The following project documents should be produced as a minimum to cover the design of the Civil Works: Front end engineering design (FEED)

General Arrangement Drawings Overall Site Plan Plot Plans Calculations Basis of Design

Detailed design

General Arrangement and Detail Drawings Overall Site Plan Calculations Bar Schedules




Survey Drawings Design Specification

9.0 CERTIFYING AUTHORITY REVIEW REQUIREMENTS

Some plants may require the design to be certified or validated by an independent certification authority due to local regulations or as instructed by OMV. Under these circumstances the certifying authority will require as a minimum the following documents for review:

General Arrangement Drawings Detail Drawings Overall Site Plan Calculations Design Specification

These should be issued to the CA in a timely manner to obtain approval before commencing construction.

PREFACEDEFINITIONSABBREVIATIONSINTRODUCTIONAPPLICABLE CODES, STANDARDS AND REGULATIONSCodes and Standards List

DESIGN GUIDELINESDesign LoadsLoad CombinationsMiscellaneous LoadsPermissible StressesStability (Pad Type Foundations)GroutingBaseplate LevelsReinforced Concrete Foundations and StructuresDesign MethodsSpread FoundationsSlidingUplift

Machinery FoundationsAnalysis

ConcreteReinforcing SteelDesign and Construction of Roads

CONSTRUCTIONGeneralMaterialsConcrete Mix Design, Proportioning and MixingConcrete Transport and PlacingFormwork and FinishReinforcement

DOCUMENTATION REQUIREMENTSCERTIFYING AUTHORITY REVIEW REQUIREMENTS

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Documents