P133I Concrete

C.A.T.
GROUP QUALITY ASSURANCE
INSPECTION AND TESTING FOR CONCRETE WORKS

REVISION 0 DATED 20.04.2014
CONTRACT NUMBER 6600032833

BI-10-01282
MASTER GAS SYSTEM (MGS)
56"EGW-2 LOOP-1
FOR
SAUDI ARAMCO
Inspection and Testing for Concrete Works
(QA/P133I.Doc)
0
Rev
QC Manager
Prepared By
QC Manager
Controlled By
20.04.2014
Date
Project Manager
Approved By
C.A.T. GROUP QUALITY ASSURANCE

Table of Contents
1.
PROCEDURE NO.
2.
SCOPE AND PURPOSE
3.
APPLICABILITY
4.
RESPONSIBILITY
5.
GENERAL
6.
DEFINITIONS
7.
PROCEDURE
7.1.
Receiving Inspection
7.2.
In-process Inspection and Testing

7.2.1.
7.2.2.
7.2.3.
7.2.4.
7.2.5.
7.2.6.
7.2.7.
7.2.8.
7.3.
Civil and Earth Works

Pre-Pour Inspection
Concrete Placement
Concrete Testing
Form Removal
Concrete Curing and Protection
Finishing
Grouting
Final Inspection and Testing
8.
RECORDS
9.
REFERENCES
10.
ATTACHMENTS
1.

PROCEDURE NO.
P133I
2.
SCOPE AND PROCEDURE

The scope and purpose of this procedure is to establish a functional Inspection and
Testing system to ensure that the process control of concrete works is adopted and
properly executed in accordance with Client specifications and applicable standards.
3.
APPLICABILITY
All Concrete works.
4.
RESPONSIBILITY
5.
Project Manager
Discipline Engineer
Discipline Foreman
QA Manager
QC Personnel
Material Controller
GENERAL
The responsibility for the Inspection and Testing of the Concrete Works rests primarily
with the QC Inspector, the Discipline Engineer and the Discipline Foreman with audit
by the Senior QA/QC Personnel .
The Discipline Engineer and the Discipline Foreman shall ensure the required work
permits are available and in place on a daily basis. Similarly they shall ensure that
utilized drawings are latest revision
The Project QA & QC Managers shall verify compliance to this procedure by Audit,
and shall perform reviews on all Quality related contractual documentation
The QC Inspector shall be responsible for witnessing tests and inspections and
ensure appropriate documentation in accordance with relevant SATIP.
All forms and records shall be filled out in accordance with the relevant SATIP. Client
SATIP and records are referenced however should the need arise additional forms
shall be developed for specific activities and added as the project progresses
Concrete works shall comply fully with the applicable laws and Client requirements
and specifications.
3
6.
DEFINITIONS
SATIP:
SAIC:
SATR:
7.

Saudi Aramco Typical Inspection Plan.

Saudi Aramco Inspection Checklist.
Saudi Aramco test Record.
PROCEDURE
7.1.
Receiving Inspection
The cement aggregates and water used shall be in accordance with SAES-Q001. The QC Inspector and Material Supervisor shall control, through the proper
SATIP and procedure that cement, raw materials and concrete reinforcement,
are in compliance.
The Quality Department shall submit to Client Representative, full details of all
materials to be used for the concrete works including, if required, the names of
suppliers or manufacturers and sources of supply, for his review and approval
In accordance with SATIP-Q-001-01.
The Quality Department shall ensure that materials or sources of materials are
not changed. Materials where required, shall be sampled and tested in an
approved laboratory. Results of tests shall be submitted to Client
Representative.
7.2.
In-process Inspection and Testing

7.2.1. Civil and Earth Works (SATIP-A-114-01/ SATIP-S-070-01)
Inspection and Testing of Civil and Earth works shall be done in
accordance with SAES-M-100,SAES-A-114 and Procedure P138I.
7.2.2. Pre-Pour Inspection (SATIP-Q-001-02)
a) Forming
Prior to the placing of concrete, the Discipline Engineer / QC
Inspector must ensure that the forms comply with SAES-Q-001 Sect
8
b) Reinforcement
The reinforcing steel must be in accordance with SAES-Q-001 Sect
5 & 6 and be checked for the following:
4

The steel is clear of the forms and soil and held firmly in place
by the use of wires, chairs, or spacers.
Mud, oil, concrete and loose scale has been removed.
The steel has been installed in accordance with the foundation
drawings and bending schedule as to size, location and
spacing. The splicing and radius of bends conforms to the
project specifications.
c) Embedded Items (SATIP-Q-001-02)

Embedded items must be checked as follows:
The Discipline Engineer shall check the diameter, length, type,

location, elevation, projection and plumb ness of anchor bolts.
They must be properly secured.
The sleeves for anchor bolts must be checked for correct size
and material, and must be centered on the bolts.
Angles, inserts, plates, sleeves, block-outs and hold-downs shall

be checked for size, thickness, material and location.
Check for installation of conduits and ground wires, when

required.
d) Approval to Pour
Concrete foundations shall not be poured until the QC Inspector or
Client Inspector has completed pre-pour inspection.
Relevant SAIC/SATR shall be used to indicate acceptance to pour.
7.2.3. Concrete Placement (SATIP-Q-001-02)
Previous to, or during the placing of the concrete, the Discipline
Engineer shall check for the following:
a) Concrete surfaces to receive new concrete should have the
loosened particles of aggregate and dirt or mud removed.
b) The ground or existing concrete should be moistened with water.
c) The minimum mixing time should be sufficient to form the uniform
mass and not exceed the time limit for remaining in the mixer.
d)

When applicable, the slump must be checked to avoid placing

concrete too wet. Water shall not be added to concrete in the field.
e) Equipment made of aluminum or aluminum alloy should not be

used to transport or convey concrete.
f)
All concrete should be thoroughly consolidated by vibrating, but

should not be over-vibrated.
g) Concrete should not be dropped in tall forms without a drop pipe,

moved with a vibrator, nor handled with any other manner, which
could cause separation of materials.
h) In making large pours, an efficient system of placing concrete
should be set up to keep the edges fresh or soft, in order to avoid a
cold joint if there is an unexpected delay.
7.2.4. Concrete Testing (SATIP-Q-001-02)
The Saudi Aramco Approved Third Party Technician is responsible for
the testing of concrete as follows and in accordance with SAES-Q-001,
09-SAMSS-97:
When applicable, slump tests for consistency of a concrete batched

mix should be made as per the project specifications. The Saudi
Aramco Approved Third Party Technician should make this test by
taking concrete sample from the truck spout or from the fresh
concrete as it is placed in the forms. A well-proportioned concrete
mix with proper water content will gradually slump but retain its
original cohesive form. A poor mix with excessive water content will
slump quickly, aggregates will separate, and the specimen will
disintegrate. Acceptance criteria of a slump test shall be in
accordance with the specifications.
Cylinder Test shall be done in accordance with 09-SAMSS-97.
Specimens for each set shall be obtained at the same time and from the
same batch of concrete. A standard slump test shall be made each time
compression test cylinders are taken.
Test cylinders shall be dated and numbered consecutively. Each
cylinder of each set shall also be given an identifying letter (A, B etc.)
At least four cylinders shall be made at one time and tested as follows:
1 Cylinder at 3 Days.
1 Cylinder at 7 Days.
2 Cylinders at 28 Days.
6

Relevant SAIC / SATR shall be used for reporting on cylinder

testing.
A concrete test specimen report must be completed when

specimens are taken for testing. A standard form supplied by the
testing laboratory will be acceptable. The original of this form should
be forwarded to the Site QC Office and one copy must be sent to the
laboratory along with the specimens.
7.2.5. Form Removal (SATIP-Q-001-02)
Determining the time for safe form removal should be based on

the effect on the concrete. There must be no evidence of damage
to the concrete due to stripping operation. The minimum time for
walls or columns, sides of beams, footings, manholes and block
foundations should be 24 hours.
Unless otherwise specified, the shoring under beam bottoms and

supported slabs may be removed after test results indicate that
the concrete has reached 2/3 of the design strength. (in special
cases, such as precast concrete, architectural concrete and long
spans, the Client should be consulted).
Care must be exercised when removing forms to ensure that the

bolts are not disturbed and the concrete is not damaged.
7.2.6. Concrete Curing and Protection (SATIP-Q-001-02)
The concrete should be kept continuously moist for the duration

specified in accordance with SAES-Q-001 Sect 10.
7.2.7. Finishing (SATIP-Q-001-02)

1. All concrete finishing will be in accordance with the approved
project drawings and Client specifications.
2. The finishing of concrete foundations and walls can best be
accomplished immediately after the removal of forms.
3. All concrete shall be inspected to determine that voids, form tie
holes, damaged corners, etc., have been properly repaired.
4. Finished concrete must be protected and cured as specified in
the preceding paragraphs.

5. Contraction joints in concrete slabs that require sawing will be

cut within the time limit specified in the Client specifications.
6.
Coating for underground portion of foundations shall be done in

accordance with SAES-Q-001, SAES-H-101, APCS 10 and
Coating application shall be recorded on Form P143-2 Paint
Acceptance Report.
7.2.8. Grouting (SATIP-Q-010-01)
7.3.
The Discipline Foreman shall ensure that grouting is mixed and applied
in accordance with SAES-Q-010 and Manufacturers recommendations
and instructions.
Final Inspection and Testing (SATIP-Q-001-02)
The Saudi Aramco Approved Third Party Technician shall prepare, mark, store
and cure test cylinders as per the Client Requirements and specifications.
The results of the tests shall be submitted to client Representative in the period
required in the specifications.
Any defective concrete work shall, at the discretion of the Client
Representative, be demolished completely and rebuilt or cut and made good.
Such rectification shall be re-tested / Inspected in accordance with original
requirements
The Saudi Aramco Approved Third Party Technician shall use the Concrete
Cylinder Record Summary to keep records of the results of testing.
The documents relevant to inspection and testing shall be kept in the QA/QC
Office on Site.
8.
RECORDS
All Forms and records relevant to this procedure shall be kept in the site office by the
QA/QC Supervisor and following the finish of the project repatriated to the area head
office to be archived and kept for a period of Three years.
9.
REFERENCES
SAES-Q-001.
SAES-Q-010.
SAES-M-100.
SAES-H-101.
09-SAMSS-097.
SATIP-A-114-01
8

SATIP-S-070-01
SATIP-Q-001-02
SATIP-Q-010-01
10.
ATTACHMENTS
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C.A.T.

GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

CONTRACT NUMBER 6600032833

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

SCOPE AND PURPOSE

In-process Inspection and Testing

Civil and Earth Works

Final Inspection and Testing

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

SCOPE AND PROCEDURE

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

Saudi Aramco Typical Inspection Plan.

In-process Inspection and Testing

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

c) Embedded Items (SATIP-Q-001-02)

The Discipline Engineer shall check the diameter, length, type,

Angles, inserts, plates, sleeves, block-outs and hold-downs shall

Check for installation of conduits and ground wires, when

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

When applicable, the slump must be checked to avoid placing

e) Equipment made of aluminum or aluminum alloy should not be

All concrete should be thoroughly consolidated by vibrating, but

g) Concrete should not be dropped in tall forms without a drop pipe,

When applicable, slump tests for consistency of a concrete batched

Cylinder Test shall be done in accordance with 09-SAMSS-97.

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

Relevant SAIC / SATR shall be used for reporting on cylinder

A concrete test specimen report must be completed when

7.2.5. Form Removal (SATIP-Q-001-02)

Determining the time for safe form removal should be based on

Unless otherwise specified, the shoring under beam bottoms and

Care must be exercised when removing forms to ensure that the

7.2.6. Concrete Curing and Protection (SATIP-Q-001-02)

The concrete should be kept continuously moist for the duration

7.2.7. Finishing (SATIP-Q-001-02)

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

5. Contraction joints in concrete slabs that require sawing will be

Coating for underground portion of foundations shall be done in

7.2.8. Grouting (SATIP-Q-010-01)

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR CONCRETE WORKS

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