SAUDI ARAMCO

Standard Notes Civil

QC Inspector Civil
SAEED-UL-HASSAN
SSxddssdddsssQCI Saeed—Ul-Hassan
 SAES-A-114 Excavation and Backfill
Process Industry Practices (PIP) PIP CVS02100 Site Preparation, Excavation and Backfill Specification

Brackish Water: Water with Total Dissolved Solids of 10,000 ppm or more. Compaction water shall be tested for Total
Dissolved Solids, Chloride (Cl-) and Sulfate (SO4) contents according to SAES-Q-001. Water used for compaction of fill
material shall be reasonably free of salts, oil, acid, alkalis, organic matter, or other deleterious substances.

Clean Sand: Soil meeting the following gradation containing less than 3% Wt. of organic material.

Sieve Size Percent Passing

¼ in (6.25 mm) 100

No. 10 (2.00 mm) 90 - 100

No. 200 (0.075 mm) 10 or less

Dune Sand: Wind-deposited sand consisting of relatively single-sized particles generally passing the No.16 sieve (1.18
mm) and usually containing less than 10% soil particles passing the No.200 sieve (0.074 mm).

Marl: A wide variety of calcareous soil materials found in Saudi Arabia which may vary from clay to gravel sizes and
often include cobble and boulder sized pieces.

Controlled Low Strength Material (CLSM): A flow able, self-compacting, cementitious material used primarily as a
backfill in place of compacted fill. CLSM is recommended where traditional compaction is difficult (i.e., narrow or
congested excavation backfill). The mix design shall be 28-day compressive strength between 0.7 and 1.4 MPa (100 &
200 psi), pretested using the actual raw materials and approved by the Chairman, Civil Standards Committee before
use on the project. Minimum of 6 hours prior to proceeding with construction over the CSLM.

General Fill Material: General Fill Material shall consist of gravel, sand and/or marl. The maximum size shall be one-
half the lift thickness or 75 mm (3 inches).Fill material shall be free of frozen lumps, organic matter, trash, chunks of
highly plastic clay or other unsatisfactory material. General Fill Material shall be placed in lifts of 300mm max. In loose
depth. General Fill Material and Select Fill Material shall be placed in lifts of 100 mm max. In loose depth for hand-
operated compaction equipment.

General Fill Material for areas not designated as open or landscaped:

• At least 90% of the maximum Modified Proctor density as determined by ASTM D1557

• At least 70% Relative Density as determined by ASTM D4253 and ASTM D4254 for cohesion less

General Fill Material for areas designated as open or landscaped:

• At least 85% of the maximum Modified Proctor density as determined by ASTM D1557

• At least 65% Relative Density as determined by ASTM D4253 and ASTM D4254 for cohesion less granular soils that
do not exhibit well-defined moisture density relationship.

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Select Fill Material: “Structural Fill” shall be composed only on inorganic material & shall have 100% passing the 5cm
(2 in) sieve & from 0 to 20% passing the No. 200 sieve. The portion of Select Fill material passing the No. 40 sieve shall
have a Max. Liquid limit of 35 & Max. Plasticity index of 12 per ASTM D4318. Liquid limit and plastic limit tests are
not required for select fill material with less than 15% passing the No. 200 sieve.

Within 0.6 m of the bottom elevation of foundations, spread footings, slabs-on-grade and pavements when fill is
required to achieve final grade. Select Fill Material shall be placed in lifts of 200 mm Max. In loose depth.

The moisture content of the material being compacted shall be within 3% plus or minus of the optimum moisture
content as determined by ASTM D1557.

All Select Fill Material and any fill beneath and/or adjacent to foundations, grade beams, mats, buildings, lined slopes
or drainage channels, and process areas:

• At least 90% of the maximum Modified Proctor density as determined by ASTM D1557

• At least 70% Relative Density as determined by ASTM D4253 and ASTM D4254 for cohesion less

Select Fill Material beneath and/or adjacent to foundations with static loads over 320 kPa and foundations for
vibrating or heavy machinery:

• At least 95% of the maximum Modified Proctor density as determined by ASTM D1557

• At least 85% Relative Density as determined by ASTM D4253 and ASTM D4254 for cohesion less

Asphalt and concrete pavement sub grades:

• At least 95% of the maximum Modified Proctor density as determined by ASTM D1557

• At least 85% Relative Density as determined by ASTM D4253 and ASTM D4254 for cohesion less

Testing and Inspection Requirements Laboratory Control Tests:

Tests of gradation, plasticity, density, and moisture content shall be performed for each type of fill material. These
tests shall include the following:

Required tests for cohesive soils:

1. Sieve analysis (ASTM C136, ASTM D422, or ASTM D1140)

2. Plasticity Index determination (ASTM D4318)
3. Modified Proctor Test (ASTM D1557) with corresponding Proctor curve.

Required tests for cohesionless soils:

1. Sieve analysis (ASTM C136, ASTM D422, or ASTM D1140)

2. Relative Density determination (ASTM D4253 and ASTM D4254).

Laboratory Control Test Frequency:

A minimum for every 5,000 m3 using a combined sample of four random samples of the fill material.

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Field Control Tests:

1. Sand-cone method in accordance with ASTM D1556

2. Nuclear method in accordance with ASTM D6938
3. Rubber balloon method in accordance with ASTM D2167
4. Drive-cylinder method in accordance with ASTM D2937. The drive- cylinder method per ASTM D2937
may only be used if the compacted layer is only 15 cm or less.

Testing shall be performed at the following frequencies:

1. Select Fill Material under all foundations, buildings and process areas - one test every 100 m² of each
lift.
2. Select Fill Material under roadways, railroads, area pavement and parking areas, and lined slopes or
drainage channels - one test every 200 m² of each lift
3. General Fill Material - one test every 500 m² of each lift.
a. Backfill of trenches - one test for every 15 linear meter of each lift.

Site preparation:

1. Areas shall be free of organic material, trash or other unsuitable material.

2. Proper drainage so that the site is free of standing water all the time.
3. In-situ soil proof rolled and inspected for soft spots or loose zones. Proof roll may be defined as
crossing the area with a heavy (minimum 10-ton weight) rubber-tire or steel-wheel roller.
4. All observed soft spots or loose zones shall be compacted in-place or excavated to firm soil and
replaced with properly compacted fill.
5. Top 6 inches (150 mm) scarified and re- compacted.

QCI Saeed-Ul-Hassan
 SAES-Q-006 Asphalt and Sulfur Extended Asphalt Concrete Paving
Specification for Preparation of Subgrade Materials:

1. The entire subgrade shall be compacted to not less than 95% of the Max. Dry density per (ASTM D1557, or
AASHTO T180) while within +/- 1.5% of the optimum moisture content or to 85% of relative density
determined by ASTM D4253 and ASTM D4254.
2. The subgrade shall be constructed so that after being compacted, it will conform to the alignment, grade, and
cross-section shown on the plans, which shall not vary by more than +/-20mm or as required by the Project
construction specification.
3. Soil characteristics of subgrade materials shall be verified by CBR of laboratory compaction, ASTM D1883.
Where existing subgrade materials have a CBR of 5 or less, a subbase with a minimum CBR of 15 shall be
provided with a minimum thickness of 20 cm. (CBR shall be as determined by ASTM D1883 at 95% compaction
according to ASTM D1557 or AASHTO T180).
4. The subgrade shall be checked and approved by the Saudi Aramco representative prior to starting
construction of sub base and base on any portion of work.

Placing:

 Granular subbase and base material shall be placed in layers of uniform thickness with approved spreaders.
Layer thickness shall not exceed 150 mm after compaction.

Compaction:

1. The water content of the material shall be maintained during compaction at the optimum percentage (±1.5%)
as determined by ASTM D1557 or AASHTO T180.
2. The rolling shall continue until the base and subbase are compacted to not less than (98% for the base and
95% for the subbase) of the Max. Laboratory dry density ASTM D1557 or AASHTO T180. In-place density shall
be measured by ASTM D6938 or ASTM D1556 or other approved methods.
3. Aggregate base and sub base compaction testing shall be conducted at a frequency of 1 test per 500 sq.m.
Each test is made by the average of 3 readings within the radius of 2 m.

Finishing:

 The surface of the completed aggregate subbase shall not show any deviation in excess of ±20mm and ±10mm
for base course. The completed thickness of the base shall be within ±6 mm of the thickness indicated and the
average thickness shall not be less than the design thickness.

Specification for Prime Coats and Tack Coats:

Prime Coat:

1. The prime coat shall be applied and shall consist of MC-70 or MC-250 conforming to the requirements of MOT
2. A prime coat shall consist of the initial application of liquid asphalt into the surface of non-asphalt base
course.
3. Prime coat shall be tested as per AASHTO R 66 for a maximum of 37,800 liters usage or 31,500 m² coverage
prior to applications.

4. The atmospheric temperature is 16°C or above.

5. A pressure distributor at a rate between 0.65 and 1.75 liters per square meter.
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 6. A temperature b/w 50°C and 80°C for MC-70 & 65°C and 105°C for MC-250 as per ASTMD2995.
7. The temperature of the MC material shall be maintained at least 10°C below the flash point of the material.
8. The prime coat materials shall be applied to a width of 300 mm greater on each side of the road than the
specified width of the finished surface.
9. The curing period be less than 24 hours. The prime coat shall be fully set and cured before placing an asphalt
mixture on the base.

Tack Coat:

1. A thin layer of asphalt that ensures the bonding b/w old & new asphalt layer.
2. Tack coat shall be tested as per AASHTO R 66 for a maximum of 37,800 liters usage or 31,500 m²
coverage prior to applications.
3. Bitumen distributor at a maximum rate of 0.25 liters per square meter as per ASTM D2995.
4. The atmospheric temperature is less than 16°C.
5. RC 70 & RC 250.

Job Mix:

The Job-Mix Formula (JMF) shall be evaluated, tested and certified by an SA approved civil testing laboratory and be
approved by Saudi Aramco. Accordance with ASTM D2172 or ASTM D6307.

Material Percent

Total Mineral Aggregate 93 – 96

Asphalt Binder 4–7

30% by weight of the bitumen (asphalt binder) in the mix shall be replaced with pelletized elemental sulfur. The
maximum mixing temperature for sulfur extended asphalt mixtures is 140°C.

Exception:

Sulfur Extended Asphalt is not required for:

1. Pavement New Construction and Maintenance within live plant areas.

2. Maintenance work that includes handwork.

3. Pavement New Construction and Maintenance within occupied residential areas.

Placement of Hot Mix Asphalt Concrete:

1. Temperature of sulfur extended asphalt mixtures shall be between 130 and 140°C when it leaves the plant.
2. A temperature of at least 115°C at the time of spreading and compaction.
3. Temperature of mixtures without sulfur shall be between 139°C and 163°C.
4. Leaves the plant and at least 139°C at the time of spreading and compaction at the site.
5. Ambient temperature is 4°C or above.

QCI Saeed-Ul-Hassan
 Placement, Compaction and Thickness:

1. Existing pavement shall be saw-cut and tacked, and the base course shall be primed prior to placing new hot
mix asphalt.
2. Steel skid equipment shall not be used for placing hot mix asphalt until after the first layer is placed.
3. Bituminous mixture shall be spread in a placement thickness so that after rolling, the nominal thickness of
the compacted bituminous material shall not be more than 70 mm per layer.
4. The in-place density result on compaction shall be equal to or greater than 95% for the bituminous base and
wearing course of the Marshall density per ASTM D6926. Using material sampled at the road site.
5. All compaction shall be completed before the temperature of the mixture drops below 90°C.
6. In no case shall thin layers of materials be added to the top of the wearing course in order to achieve the
required thickness or specified tolerances.
7. Areas of base course asphalt pavement which fail to meet the required tolerances / compaction shall be
removed by saw cutting to the full depth of the course, forming parallel and perpendicular lines to the
architectural features where practical. Any wearing course which fails to meet the required tolerances and
compaction should me milled to achieve required compaction and tolerances. The area for repair shall then
receive an additional tack coat prior to placing asphalt materials.

Protection:

 Asphalt pavement shall not be in contact with pipelines that are catholically protected.
 After final compaction & rolling, vehicular traffic should not be permitted on asphalt concrete for at least 24
hours and until pavement has hardened sufficiently.

Compacted Asphalt Concrete:

1. Compaction and thickness of compacted asphalt concrete shall be accepted by lot. Unless otherwise stated in
the project documents, the lot size shall be the lesser of ten thousand (10,000) square meters, or the
production of a single day for each layer constructed.
2. Cores for density and thickness shall be taken daily from previous days production. Each core shall be legibly
and permanently marked as to the location from which the core was taken. A minimum of five (5) cores of
randomly selected location shall be tested for each lot.
3. The average actual in-place density from the five cores shall be compared with the bulk density determined
by ASTM D2726 of samples prepared by the Marshall method at 75 blows per side – ASTM D 6926.
4. Saudi Aramco representative may reduce the required number of cores to three (3) cores per lot, for lots
smaller than 1800 sq. meters.

Uncompacted Asphalt Concrete:

Samples for extraction, gradation and Marshall Properties shall be taken daily at the following rates of production:

Extraction/Grading Marshall Properties

0 to 500 tons 1/200 tons 1/250 tons

501 to 800 tons 1/250 tons 1/300 tons

801 and above tons 1/300 tons 1/400 tons

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Equipment:

1. All weighing scales for mineral aggregates and bitumen shall be calibrated and certified within the 6-month
period before use by one of Saudi Aramco approved calibration agencies.
2. All temperature gauges and thermometers shall be calibrated and certified two times a year by one of Saudi
Aramco approved calibration agencies.
3. All laboratory scales and balances, including drying ovens, shall be calibrated and certified two times a year
by a Saudi Aramco approved agency.

Plant QC Equipment:

1. Gradation of fine and coarse aggregate

2. Specific gravity of aggregate
3. Sand Equivalent
4. Plasticity Index
5. Flat or elongated particles by weight
6. Asphalt extraction and gradation

Polymer-Modified Hot Mix Asphalt Concrete (PMA):

1. Where sulfur extended asphalt paving is not used Polymer Modified Asphalt (PMA) can be used as an
alternative.
2. PMA can be used in locations like gates, heavy truck traffic areas and terminals to improve pavement
durability.
3. The mixing temperature for the binder shall be 170 +5°C.
4. The polymer modified asphalt mix shall be placed and compacted at a temperature determined from the
viscosity-temperature relationship which is estimated to be in the range of 155 to 165°C.

QCI Saeed-Ul-Hassan
 SAES-Q-001 Criteria for Design and Construction of Concrete Structures
PIP CVC01015 Criteria for Civil design concrete

Self-consolidating Concrete: Fresh concrete that can flow around and encapsulate reinforcement and consolidate
within formwork under its own weight without any mechanical consolidation and vibration.

Hot Weather Concrete: Can be defined as job-site conditions that accelerate the rate of moisture loss or rate of
cement hydration of freshly mixed concrete, including an ambient temperature of 29°C or higher, and an evaporation
rate that exceeds 1 kg/m²/h. Limit the maximum allowable fresh concrete temperature to 35 °C (95 °F).

Mass Concrete: Any volume of concrete with dimensions large enough to require that measures be taken to cope with
generation of heat from hydration of the cement & attendant volume change to minimize cracking.

Cracks may cause: Cracks generated due to thermal gradients may cause

1. Loss of structural integrity

2. Loss in durability
3. Excessive shrinkage

Method of Temp. Control:

1. Low heat materials

2. Pre cooling of concrete
3. Post cooling of concrete
4. Surface insulation

Materials:

1. Portland cement shall be in accordance with ASTM C150/C150M, Type I or Type V.

2. Fly ash shall be in accordance with ASTM C618.
3. Ground Granular Blast Furnace Slag (GGBFS) shall be in accordance with ASTM C989/C989M.
4. Natural Pozzolan shall be in accordance with ASTM C618.
5. Silica fume shall be in accordance with ASTM C1240.
6. Reinforcing bars shall be deformed steel in accordance with ASTM A615/A615M, Grade 420.
7. Coated reinforcements shall be Fusion Bonded Epoxy in accordance with 09-SAMSS-106.
8. Tie wire shall be black annealed wire, 16 gage (1.29 mm) minimum. Fasten epoxy-coated reinforcement with
tie wires coated with epoxy.
9. Details and dimensions of the concrete masonry units shall be as shown on Standard Drawing AA-036602.
10. Below floor vapor barrier shall be in accordance with ASTM E1745, Class A, and minimum 10 mil (250 μm)
thickness unless otherwise specified in contract documents.

Concrete paving shall be in accordance with the following:

1. Areas subject to spills, wash water, fire water and sidewalk shall be paved with a min. thickness of 100 mm of
reinforced concrete.
2. Paving slabs subject to vehicular traffic shall be a minimum thickness of 150 mm of reinforced concrete.
3. Concrete paving slope to the catch basins or trenches shall not be less than 1:65 (1.5%).The maximum drop to
catch basins from high point of paving shall be 200 mm.
4. Where foundations protrude through the paving, 12 mm diameter reinforcing bars, 800 mm long, shall be
placed diagonally in the paving at all interior corners.
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Exposures:

1. Environmental concrete structures shall have a minimum 28-day design compressive strength of 35 MPa
(5,000 psi).
2. Unreinforced concrete of no significant structural value such as lean concrete for sub-slabs shall have a
minimum 28 day design compressive strength (ASTM C39) of 14 MPa (2,000 psi).

FRP Reinforcement (Fiber Reinforced Polymer Bar):

1. FRP reinforcement shall be used to replace steel reinforcement for non-critical structural elements in C1 & C2
exposures.
2. Including but not limited to, slab on grade, sidewalks, surface drainage channels, concrete paving, pipe
sleepers.
3. FRP reinforcement may add value such as Magnetic Resonance Imaging (MRI) room in hospitals, electrical
equipment foundations, sewage treatment plant, and sea walls shall be investigated.

Placing Concrete:

Concrete shall be placed in accordance with ACI 301-16, ACI 304R and this standard.
1. Equipment made of aluminum alloys shall not be used for pump lines, tremies, or chutes used to discharge
concrete from a truck mixer.
2. Raking shall not be used for movement of concrete after placement.
3. Vibrators shall not be used to move concrete inside forms.
4. Re-tempering after concrete is mixed shall not be permitted.
5. The interval between concrete deliveries shall be such that no more than 20 minutes interruptions elapse
during placement of a single foundation or slab, unless approved by Saudi Aramco.

Curing:

1. Maximum total dissolved solids in water used for curing shall not exceed 1,000 parts per million.
2. Water curing shall be continuous until the compressive strength has reached 70% of the specified strength,
but not less than 7 days.
3. The saturated burlaps shall be covered with a plasticized sheet vapor barrier, minimum 0.15 mm (6 mils) in
thickness and shall be kept in contact with the concrete surface at all times.
4. Curing shall occur for a minimum of 14 days.

Coating and Protection:

1. A plasticized sheet vapor barrier in accordance with ASTM E1745, Class A, minimum of 0.25 mm (10 mils) in
thickness, shall be placed beneath slabs on grade.
2. A minimum of 50 mm sub-slab (lean concrete) shall be placed beneath concrete foundations.
3. All concrete surfaces in direct contact with earth shall be coated with two coats of coal tar or bitumen coating
that conforms to APCS-3 or APCS-10 of SAES-H-001.
4. Minimum of 0.25 mm (10 mils) in thickness shall be placed below and around the sides of concrete that is
placed directly into excavation without the use of formwork, where coal tar or bitumen coating cannot be
applied.

QCI Saeed-Ul-Hassan
 SAES-Q-005 Concrete Foundations
PIP STE05121 Anchor Bolt Design Guide

Anchor Rods:

1. Anchor rods shall be in compliance with Standard Drawing AA- 036322-001 (Rev. 08 or later).
2. Material selection and galvanizing of anchor rods assemblies shall be per the requirements in 12- SAMSS-007.
3. The minimum anchor rod diameter shall be 20 mm (¾”).
4. Minimum clear distance from anchor rod to edge of concrete shall not be less than 100 mm.
5. Metallic anchor rod sleeves are not permitted.
6. The design of anchor rods shall be in accordance with the requirements of SAES-Q-304 Chapter 17.

Bolt Torque: Twisting force measuring force multiplied by distance.

Criss-cross Pattern: When tighting & loosing parts with a simple square pattern or circular bolt pattern.

Sleeve type:
1. Partial sleeve is primarily used for alignment requirements.
2. Full sleeve is used for alignment as well as for pretensioning.

Edge Distance: Cast-in handed anchor that will be torque to have min. edge distance of 6D
Edge distance for anchor bolts in machinery foundation is 4D, 6 inches minimum.

Spacing B/W for Anchors: Min. spacing b/w anchors to be at least 4D for untorque cast-in anchors & 6D for torque
anchors.
1. Types 1/1s ASTM-A307
2. Type 2/2s ASTM-A-36
3. Type 3/3s ASTM-A-193

Formula:
Double Nut Bolts (130mm)
 Thickness of grout + Thickness of plate + 2.5*dia of bolt
Single Nut Bolt (10mm)
 Thickness of grout + Thickness of plate + 1.5*dia of bolt

Post-Installed Anchor Rods:

1. Anchor rods for connecting structural elements to the foundation that are not cast into the concrete.
2. Post-installed anchor rods are typically installed in a hole drilled into hardened concrete and bonded
to the foundation using a proprietary epoxy adhesive
3. Post-installed anchor rods in foundations shall not be used for new construction unless shown on
design drawings.
4. Post-installed anchor rods are permitted for repair and replacement of missing or damaged existing
anchors if the post-installed anchors are designed, installed.

QCI Saeed-Ul-Hassan
 SAES-Q-010 Cement Based, Non-Shrink Grout for Structural and Equipment Grouting
Process Industry Practice STS03600 Non-shrink Cementitious Grout Specification

1. Cementitious grout is used in the foundations of static equipment, structural base plates, anchor bolts,
precast members, i.e., wall panels, beams, post tension ducts, etc.
2. Minimum 28 days compressive strength shall be 34.5 MPA (5,000 psi).
3. Where true non-shrink characteristics are not mandatory, site mixed grout shall use clean well graded sand
that meets the requirements of 09-SAMSS-088, Type V Portland cement ( ASTM C150) and potable water.
Minimum 28-day compressive strength shall be 13.8 MPA (2,000 psi).
4. Total dissolved solids (TDS) for mixing and curing water shall not exceed 500 ppm.
5. Grout shall be free of hydrogen gas producing, oxidizing catalysts and inorganic accelerators.
6. Concrete foundations shall be cured for a minimum of 7 days before surface preparations for grouting.
7. Laitance, oil-soaked or damaged concrete shall be removed down to sound concrete by chipping to the level
of sound fractured aggregate or to a minimum of the top 1 inch (25mm) of the concrete.
8. Grout shall be mixed per the Grout Manufacturer's instructions.
9. The minimum thickness of the grout shall be the space between the bottom of the base plate and the top of
the concrete foundation; the minimum thickness of grout shall be 25mm.
10. Grout shall be placed in only one direction to prevent trapping air; Grouting shall be quick and continuous to
avoid segregation, bleeding or premature initial set.
11. The temperature of the grout when placed shall be 230C + 30C. (ASTM C 1107).
12. Two sets of 3 grout test cubes shall be cast in the field for each day that grout is mixed and placed.
13. Cure the cubes in the field for three (3) days in the same way as the placed grout is cured.
14. Test compressive strength of cubes in accordance with applicable provisions of ASTM C109. Test one cube set
at 7 days and one cube set at 28 days.
15. When the grout's water/cement ratio is 0.4 or less, the grout shall be given a continuous water cure (covered
by wet burlap and 0.15mm polyethylene) for a minimum of 7 days. (ASTM C309)
16. The grout shall be tooled to a 45 angle down from the bottom of base plates after it has reached its initial set.

QCI Saeed-Ul-Hassan
 SAES-Q-011 Epoxy Grout for Machinery Support
Process Industry Practices PIP STS03601 Epoxy Grout Specification

Resin: Component shall consist of a pre-measured, prepackaged, solvent free, liquid epoxy resin specifically
formulated for the used grout system.

Hardener: Component shall consist of a pre-measured, prepackaged liquid specifically formulated to produce the
specified final properties when mixed with the other component.

Aggregate: The aggregate shall be a pre-measured, prepackaged blend of inert, inorganic particulate fillers, such as
silica, designed specifically to provide the proper flow, handling and physical properties required for the grout
product.

1. The ratio of aggregate to resin and hardener shall be per the manufacturer recommendations. If aggregate
ratio is adjusted for field conditions, physical properties shall be obtained at the recommended fill ratio.
2. Expansion joints shall be incorporated into large epoxy grout pours to reduce the possibility of cracking,
especially when machinery-to- grout temperature differentials of 30°C are encountered. Expansion joints
should be placed at approximately 1.2 m to 1.8 m intervals in the grout foundation.
3. A layered combination of non-shrink cement and epoxy grout may be used, as permitted by SAES-Q-007 for
large baseplates that have structural webs deeper than 230 mm.
4. Maximum linear shrinkage (ASTM C531): 0.080 percent.
5. Minimum bond strength of epoxy grout to concrete (ASTM C882): 2000 psi (14 MPa)
6. Fifteen days before installation, the contractor shall submit for review and acceptance, a written quality
control program. The program shall include all forming, handling, mixing, placing, joint locations, joint details,
curing, testing, and inspection procedures
7. The minimum compressive strength (ASTM C579, Method B) is 12,000psi (80 Mpa) at 7 days.
8. Grout are applied only when surrounding temperatures are between 15°C and 32°C (60°F and 90°F) unless
otherwise specified in the manufacturer's data sheets.

QCI Saeed-Ul-Hassan
 SAES-H-003 Protective Coatings for Industrial Concrete Structures
Saudi Aramco Approved Protective Coating System (APCS)

Buried (Foundation, Columns, Walls):

1. Coat buried concrete surfaces only up to grade level if APCS-3 or APCS-10 is selected.
2. APCS-10 is not suitable for hydrocarbon contact and direct sunlight exposure.

General Requirements:

1. The purpose of surface preparation is to remove laitance, contaminants and others adhered compounds on
the concrete like the curing agents, and to create an anchoring for coatings to be well adhered with the
concrete structures.
2. Concrete surface preparation prior to coating application shall include but not limited to: Repair of cracks,
spalls, pop outs, and other irregularities, Removal of surface contaminants that inhibit coating adhesion or
induce early coating deterioration, Roughen the smooth surfaces to improve coating adhesion, and
Eliminating any weak surface layers to establish the strong base required for many coating system. Use only
approved equipment for roughening of concrete surface.
3. After cleaning is completed ensure that surfaces are free of voids which may be exposed or enlarged during
blasting process. Repair the voids if necessary.

Inspection and Testing:

The following constitute inspection hold points:

1. Prior to the start of work.
2. Immediately following surface preparation.
3. Immediately prior to coating or lining application.
4. Following the application of each coat.
5. Following the curing of the coating or lining.

Acceptance Criteria :( Surface preparation, moisture testing and environmental condition inspection)

1. The coating shall be applied after the full curing time of concrete in accordance to SAES-Q-001.
2. New concrete must have a moisture content of 4% or less before the coating applications commence.
Note: Test report SATR-H-1003 “Concrete Moisture Field Test” (For Coating Purposes).

3. Coating shall not be applied when the substrate temperature is less than 10°C; or less than 3°C above dew
point.
4. After rinsing, force air dry surfaces for at least 24 hours prior to making any repairs to the concrete.
5. Cracks less than 10 mm wide and holes not exceeding 10 mm in diameter shall be filled using a qualified
epoxy filler or grout before applying primer/sealer to the surface.

Documentation:

Reports, logs and final acceptance documents shall be reported on the appropriate forms in SAES-H-001 Attachment.

QCI Saeed-Ul-Hassan
Concrete Moisture Field Test for Coating Purposes:

Test Procedures shall be in accordance with (SAES-H-003 Sec. 8.1.4)

1. Tape a 4 mil thick (0.1mm), 18"x 18" (450mm x 450mm) of clear plastic sheet to the surface to be coated; tape
all around with duct tape.
2. Sheet shall remain in place for a minimum of 16 hours. Indicate number of hour’s sheet has been in place:
_____ hrs.
3. Remove and visually check the underside for moisture.
4. A If droplets of moisture are present, the concrete shall be given more curing time.
5. After 16 hours if no moisture is present on the inside of the plastic, the concrete is ready for coating.

Alternate Test Procedures shall be in accordance with (SAES-H-003 Sec. 9.6.9)

1. Drill 2 holes 6mm Diameter, 25mm deep and 150mm apart (holes to be repaired after test)
2. Surface contaminants such as laitance and form oils shall be removed.
3. Insert the Elcometer probes into each hole and seal in place with silicone putty.
4. Wait 24 hours for the effects of the drilling to stabilize.
5. Moisture Content Reading: ____________%
6. Begin coating only if the moisture content reading is less than 4%.

APCS-3 Type of Coating: Coal Tar Epoxy

Application:

1. Maximum Allowable Substrate Temperature: 50°C

2. Typical Wet Film Thickness Per Coat: 220 micrometers
3. Typical Dry Film Thickness Per Coat: 200 micrometers
4. Minimum Number of Coats: 2
5. Storage (Shelf life, sheltered) @ 35°C maximum : 2 years
6. Mixing: No. of Components : 2
7. Mixing Ratio: 4:1 by volume; Base : hardener

APCS-10 Type of Coating: Bituminous

Application:

1. Maximum Allowable Substrate Temperature: 45°C

2. Typical Wet Film Thickness per Coat: 605 micrometers
3. Typical Dry Film Thickness per Coat: 375 micrometers
4. Minimum Number of Coats : 2 for buried service; 3 for immersion service

QCI Saeed-Ul-Hassan
 09-SAMSS-097 Ready-mixed Concrete
Mobile Volumetric-Measurement and Continuous-Mixing: ready-mixed concrete made from materials continuously
batched by volume, mixed in a continuous truck mixer, and delivered to the purchaser in a freshly mixed and
unhardened state. SAER-10516.

Modifications:

 Ordinary Portland cement (Type I) sulfate resistant Portland cement (Type V) ASTM C150/C150M

Pozzolans:

Pozzolans that include natural volcanic ash, metakaolin, silica fume, and fly ash shall be used as follows:

Silica fume: When used as replacement for cement in concrete as binary mix, shall not be less than 7% and shall not
exceed 10% by weight of cementitious material. Silica fume can also be used in combination with other pozzolans or
Ground Granulated Blast Furnace Slag (GGBFS) when used as replacement for cement in concrete (Ternary mix).

Natural Pozzolans: (Such as volcanic ash) can be used as partial replacement of cement. The replacement shall be up
to 50% based on trial mix test results for strength, durability and heat of hydration limits.

Fly ash: Can be used as partial replacement for cement in concrete (binary or ternary mix) for durability purposes.
The amount of fly ash shall not be less than 25% by weight of cementitious material. Mass concrete fly ash content
shall be in accordance with ACI 301 chapter 8.

Ground Granulated Blast Furnace Slag (GGBFS): GGBFS can be used as partial replacement for cement in concrete
(binary or ternary mix) for durability purposes. The amount of GGBFS shall not be less than 60% and shall not exceed
80% by weight of cementitious material. Mass concrete GGBFS content shall be in accordance with ACI 301 chapter 8.

Mixing water:

1. Mixing water shall conform to ASTM C1602. When combined mixing water is used, mixing water shall be free
from oils, acids, organic matter or other deleterious substances.
2. The maximum water-soluble chloride ions in concrete shall not exceed 0.15% for reinforced concrete and
0.06% for pre-stressed concrete by weight of cement. The maximum Sulfate ions as SO3 shall not exceed 4%.
Tests shall be in accordance with ASTM C1218/C1218M.
3. Wash water shall not be used as mixing water.

Concrete slump:

 Concrete with high-range water reducing or plasticizing admixtures shall have a target or nominal
slump of 150 mm, (±40 mm) at the point of discharge at the job site or otherwise specified.

Self-consolidated concrete (SCC) concrete slump flow shall be as follows:

 Concrete with Ultra High Range Super plasticizer admixtures shall have a target or nominal slump flow
of 650 mm, (±65 mm) at the point of discharge at the job site or otherwise specified. A Slump flow test
shall be conducted per ASTM C1611/C1611M.
 When concrete pumps are used, the slump shall be determined at the discharge point of the concrete
placement hose.
QCI Saeed-Ul-Hassan
Compressive strength tests:

1. Compressive strength is required at 28 days unless when concrete contains fly ash, natural pozzolan, GGBFS or
combination of any cementitious material (binary or ternary mix), strength is required at 56 days.
2. Test one set of laboratory-cured specimens at 7 days and one set of specimens at 28 days. Additional test of
one set at 56 days for concrete containing natural Pozzolan, fly ash, GGBFS, or combination of any
cementitious material.
3. Test one set of field-cured specimens at 7 days and one set of specimens at 28 days. Additional test of one set
at 56 days for concrete containing natural Pozzolan, fly ash, GGBFS, or a combination of any cementitious
material.
4. When strength of field-cured cylinders is less than 85% of companion laboratory-cured cylinders.

The test report shall include the following data for each test sample of concrete taken at the placement site:

1. Name of Project, Job Order (JO) for the Project, and designation of the structure
2. Slump or slump flow in millimeters
3. Ambient air temperature in ºC
4. Concrete temperature in ºC
5. % Air, when air entrainment is used.

Test reports shall be submitted within 7 days after tests are completed.

QCI Saeed-Ul-Hassan
 09 SAMSS-088 Aggregate for Concrete
Calcareous Aggregates: Aggregates which composition is mainly calcite.

Non-calcareous Aggregates: Aggregates in which the calcium carbonate content is negligible.

Qualification Requirements:

1. Samples shall be taken at random and at a frequency of at least one sample per 200 m³ of aggregate to be
shipped, but not less than one sample per month. Any material failing to comply with the specification shall
be rejected.
2. A minimum stockpile of 500 m³ of each aggregate size shall be committed by the suppliers and accepted.
3. Sand shall be washed prior to batching with washing water that shall comply with the requirements of ASTM
C1602.

Aggregate Soundness test:

1. Only magnesium sulfate shall be used for the soundness test.

2. Clay Lumps and Friable Particles Monthly
3. Chert (Less than 2.4 Sp.Gr. SSD) Monthly
4. Sum of row 1 and 2 5.0(2) - - -
5. Materials finer than No. 200 Sieve Weekly
6. Coal and Lignite Monthly
7. Abrasion (Los Angeles) Monthly
8. Water Absorption Monthly
9. Magnesium Sulfates Soundness Bi-Monthly (every two months)

QCI Saeed-Ul-Hassan
 SAEP-381 Project Quality Issues Escalation Process
Purpose: The purpose of this SAEP is to:-

1. Implement a consistent method for escalating quality issues including Internal Non-conformance Reports
(INCRs), Logbook Entries (LBEs), Saudi Aramco Non-Conformance Reports (NCRs), Worksheets (WSs) and
Delinquent Worksheets (DWSs), as defined in Appendices A-1, A-2, and A-3, “Quality Issues Reporting
Process.”
2. Clearly define the corporate process for project quality issue escalation including its documentation,
requirements and definition of violation categories, systems and procedures.
3. Ensure roles and responsibilities for project quality issue escalation are well defined and auditable.

ACD: Agreed Completion Date: The date which the violation notification will be closed upon completion of the
required corrective and preventive actions for the reported violation fully.

INCR: Internal Non Conformance Report (Issued by contractor)

LBE: Logbook Entries (First level of reporting quality deficiency using Manual Logbook or the Quality Management
Information System, QMIS/EPM)

NCR: Non-conformance Report (Issued by Saudi Aramco through SAP QM). A report reporting the variation from the
specified requirements.

WS: Worksheet (Mechanism to report project major violations, repeated moderate violations or escalating overdue

NCRs as stipulated in this Procedure).

SAP QM: Systems, Applications, and Products in Data Processing-Quality Module

Violations Categories:

Major:

1. Violations of company standards including GIs that put the quality and integrity of the facility including its
workers and equipment at risk.
2. Repeat of Moderate violations

Moderate:

1. Any violation to MSAER, project specifications and approved IFC drawings that if the next phase of work
(critical path) is continued without correcting the violation.
2. Any violation to Schedule Q.
3. Repeat of minor violation

Minor:

1. Any violation to MSAER, project specifications and approved IFC drawings that may affect the quality of the
current phase of work but not necessarily affect the integrity of subsequent phases of work. i.e., the next
phase of work is not dependent on the correction of the violation.
2. Repeat of Minor INCR.

QCI Saeed-Ul-Hassan
Repeat Violation: A non-compliance of the same reference of MSAER, project specifications, or contract requirements
with the same root cause which indicate a gap or failure in certain quality process/system, repeated within six (6)
months period.

Repeat of Minor Violation within six (6) months: Repeat of Moderate or Major violation within six (6) months will
result to a Quality Notification starting at the next higher level of Violation Category and Notification.Escalate minor
violation if repeated more than 3 times within 6 months to a Moderate violation.

Repeated Internal Non-conformance Report (INCR) within six (6) months “Contractor’s Internal NCR”:

1. Escalated to SA WS if the Repeated INCR categorized as a major violation.

2. Escalated to SA NCR if the Repeated INCR categorized as a moderate violation.
3. Escalated to Violation-after-the-fact Entry in the QMIS if the Repeated INCR categorized as a minor violation.

Agreed Completion Date (ACD): For all types of quality notifications (INCR, LBE, NCR, WS, and DWS)

If the first ACD is within 90 calendar days:

1. For Minor Violations, Project Inspection Field Supervisor agreement is required.

2. For Moderate Violation, Project Inspection Unit Supervisor agreement is required.
3. For Major Violation, Project Inspection Sr. Supervisor agreement is required.

If the first ACD is exceeding 90 calendar days regardless of the violation category (Minor, Moderate, and Major):

1. Project Inspection Division Head agreement is required for ACD, if it does not exceed 180 calendar days.
2. Inspection Department Manager Agreement is required for ACD exceeding 180 calendar days.

 After the submittal of LBE to contractor and SAPMT, Project Inspection Field Supervisor is authorized to revise
the violation degree and the first Agreed Completion Date (ACD) which proposed by the Project Inspector
within 5 working days. This revision of ACD is not considered as an extension.
 After the submittal of NCR (moderate violation) to SAPMT and prior to final approval, Project Inspection Unit
Supervisor is authorized to revise the first Agreed Completion Date (ACD) within 5 working days. This
revision of ACD is not considered as an extension.
 After the submittal of WS (major violation) to Project Inspection Division Head and prior to the final approval,
Project Inspection Sr. Supervisor is authorized to revise the first Agreed Completion Date (ACD) within 5
working days. This revision of ACD is not considered as an extension.

Project Inspector:

1. Highlight to SAPMT any potential non-conforming material, product or work to avoid re-work.
2. Report in a timely manner any quality or technical deficiency through the QMIS/EPM (LBE).
3. Before LBE submittal, propose the first ACD and the degree of the violation depending on the committed
violations.
4. Support the PID Unit Supervisor in categorizing the INCR and monitoring its ACD.
5. Following-up and watching the ACD status of LBE issued by him.

QCI Saeed-Ul-Hassan
 Industry Codes and Standards
American Society for Testing and Materials
1. ASTM C136 Sieve Analysis of Fine and Coarse Aggregates
2. ASTM D422 Particle-Size Analysis of Soils
3. ASTM D1557 Laboratory Compaction of Soil Using Modified Proctor Density
4. ASTM D4253 Maximum Index Density and Unit Weight of Soils Using a Vibratory Table
5. ASTM D4254 Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density
6. ASTM D4318 Liquid Limit, Plastic Limit and Plasticity Index of Soils
7. ASTM D6938 In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods

American Association of State Highway and Transportation Officials AASHTO

AASHTO Guide for Design of Pavement Structures 1993

Ministry of Transport MOT 1998 General Specification for Road and Bridge Construction, November, 1998 Highway
Design Manuel (MOT) Volume 2 Design of Roadways.

1. ASTM C88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

2. ASTM D6926 Standard Practice for preparation of bituminous specimen using Marshall Apparatus
3. ASTM D1883 CBR of laboratory compaction
4. ASTM D2995 Tack Coat & Prime Code Residual Application Rate of Bituminous Distributors

Concrete Related:

1. ASTM A775/A775M Specification for Epoxy-coated Reinforcing Bars

2. ASTM C1116/1116M Specifications for Fiber-reinforced Concrete
3. ASTM C39/C39M Compressive Strength of Cylindrical Concrete Specimens
4. ASTM C1218 Water-soluble Chloride in Mortar and Concrete
5. ASTM C1240 Silica Fume Used in Cementitious Mixtures
6. ASTM C1580 Water-soluble Sulfate in Soil
7. ASTM C1611/C1611M Slump Flow of Self-consolidating Concrete
8. ASTM C94/C94M-21 Standard Specification for Ready-Mixed Concrete
9. ASTM C150/C150M Specification for Portland Cement
10. ASTM C595/C595M Standard Specification for Blended Hydraulic Cements
11. ASTM C685/C685-17 Concrete Made by Volumetric Batching and Continuous Mixing
12. A ASTM C33/C33M-18 Standard Specification for Concrete Aggregates
13. ASTM C1602/C1602M Mixing Water Used in the Production of Hydraulic Cement Concrete
14. ASTM-C-579 Compressive strength of mortars, grouts
15. ASTM-A-820 Steel fibers for fiber reinforced concrete.
16. ASTM-C-172 Sampling freshly mixed concrete.
17. ASTM-C-31 Making & Curing of concrete.
18. ASTM-D-4263 Indicating moisture in conc. By plastic sheet method
19. ASTM-D-5957 Flood Testing horizontal waterproofing
20. ASTM-D-1067 Acidity of water
21. ASTM C882/C882M Bond Strength of Epoxy- Resin Systems Used With Concrete By Slant Shear
22. ASTM C531 Linear Shrinkage and Coefficient of Thermal Expansion of Chemical- Resistant Mortars,
Grouts, Monolithic Surfacing, and Polymer Concretes.
QCI Saeed-Ul-Hassan
 23. ASTM C143 Slump test for hydraulic cement
24. ASTM C1181 Epoxy grout

Saudi Arabian Standards Organization:

SASO SSA 143: Portland cement, Ordinary and Rapid- hardening

British Standards: BS 1881: Part 124 Testing Concrete Methods for Analysis of Hardened Concrete

American Concrete Institute:

1. ACI 117 Standard Specifications for Tolerances for Concrete Construction and Materials
2. ACI 237R Self-Consolidating Concrete
3. ACI 301-16 Specifications for Structural Concrete
4. ACI 304R Guide for Measuring, Mixing, Transporting, and Placing Concrete
5. ACI 305R Hot Weather Concreting
6. ACI 318-14 Building Code Requirements for Structural Concrete
7. ACI 350 Code Requirements for Environmental Engineering Concrete Structures and Commentary
8. ACI 350.5 Specifications for Environmental Concrete Structures
9. ACI 440.1R Guide for the Design and Construction of Concrete Reinforced with FRP Bars
10. ACI 440.5 Specification for Construction with Fiber-reinforced Polymer Reinforcing Bars
11. ACI 562 Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings
12. ACI SP-66 Detailing Manual - Details and Detailing of Concrete Reinforcement
13. ACI 234R Guide for the Use of Silica Fume in Concrete
14. ACI 301-20 Specifications for Concrete Construction
15. ACI 308.1 Normal, Heavyweight, and Mass Concrete Cure concrete
16. ACI 360R Design of slab on ground
17. ACI 347 Formwork for concrete
18. ACI 229R Controlled Low-Strength Materials
19. ACI 212.3R Chemical admixture
20. ACI 302.1R Guide to concrete floor & slab

SCHEDULE “Q”
This Schedule describes COMPANY’s minimum requirements for CONTRACTOR’s Quality System.

1. Attachment I CONTRACTOR and Subcontractor Quality Personnel Qualification Requirements

2. Attachment II COMPANY Standards and Procedures Containing Quality Requirements
3. Attachment III Quality Requirements for CONTRACTOR Supplied Materials
4. Attachment IV Quality Requirements for the Construction Phase
5. Attachment V Summary of Quality System Deliverables
6. Attachment VI Project Specific Quality Requirements

QCI Saeed-Ul-Hassan