03150

CONCRETE BATCH PLANT AND DELIVERY

Contents

1. GENERAL

1.1 Introduction ……………………………………………......…………………... 2

1.2 Purpose …………………………………………….......……………………..... 2

1.3 Definitions ……………………………………….…….....…………………..... 2

2. CODES AND STANDARDS 2

3. DOCUMENT PRECEDENCE 3

4. SPECIFICATION DEVIATION/CONCESSION CONTROL 3

5. QUALITY ASSURANCE/QUALITY CONTROL 4

6. DOCUMENTATION 4

7. BATCH PLANT 5

8. MATERIALS 7

9. MATERIAL STORAGE AND HANDLING

9.1 Cement Storage …………………………………………….......…………….. 7

9.2 Storage of Aggregrates …………………………………………….....…....... 7

10. CONCRETE DELIVERY 7

11. FACILITIES INSPECTION AND CALIBRATION 8

12. RECORDS 8

13. REPORTS 9

DIVISION THREE - CONCRETE WORKS

CONCRETE BATCH PLANT AND DELIVERY

1 GENERAL

1.1 Introduction

This specification provides the requirements for production and delivery of

ready-mixed concrete.

1.2 Purpose

This specification provides the requirements batch plant for production and

delivery of ready-mixed concrete which includes:

Facilities for receiving, storing, handling, cleaning and proportioning

materials required to produce concrete.

Delivering concrete in appropriate transporting system to various areas of

jobsite.

1.3 Definitions

For the purposes of this specification the following definitions shall apply:

COMPANY - The Abu Dhabi National Oil Company (ADNOC).

COMPANY - The party that carries out all or part of the design,

engineering, procurement, construction and management of the total project.

PROJECT - Replace

SHALL - Indicates a mandatory requirement.

CONTRACTOR - The party that performs the work for the batch plant.

VENDOR - The party that supplies all materials to perform duties specified

by the CONTRACTOR.

2 CODES AND STANDARDS

The following codes and standards to the extent specified herein, form a part of

this specification. When an edition date is not indicated for a code or standard, the

latest edition in force at the time of CONTRACTOR’S proposal submittal shall

apply.

American Concrete Institute (ACI):

ACI 304R Guide for Measuring, Mixing, Transportation and Placing Concrete

American Society for Testing and Materials (ASTM):

ASTM C94 Standard Specification for Ready Mixed Concrete

National Ready Mixed Concrete Association (NRMCA):

NRMCA QC

3

Quality Control Manual: Section 3, Plant Certifications Checklist:

Certification of Ready- Mixed Concrete Production Facilities

International Organization for Standardization (ISO):

ISO-9001 Quality Systems - Model for Quality Assurance in Design,

Development, Production, Installation and Servicing

ISO-9003 Quality Systems - Model for Quality Assurance in Final

Inspection and Test

ISO-9004 Quality Management and Quality System Elements - Guidelines

3 DOCUMENT PRECEDENCE

It shall be the CONTRACTOR’S responsibility to be, or to become,

knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict

between this specification, the codes and Standards and any other Project

Specification noted herein. Resolution and/or interpretation of precedence shall

be obtained from the COMPANY in writing before proceeding with the work.

In case of a conflict, the order of precedence shall be:

- Purchase Order or Contract

- Project Specifications and Standards

- Industry Codes and Standards

4 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order and its attachments including, but

not limited to, the Project Specifications shall be sought by the CONTRACTOR

only through CONCESSION REQUEST format. CONCESSION REQUESTS

require the COMPANY'S review/approval prior to the proposed technical changes

being implemented. Technical changes implemented prior to approval are subject

to rejection.

Any substitution of material as an approved equal must have prior written

approval by the contractor through CONCESSION REQUEST format. The

VENDOR shall include catalog samples (if applicable) and the test data required

for proper engineering evaluation.

5 QUALITY ASSURANCE/QUALITY CONTROL

The CONTRACTOR shall have in effect at all times, a QA/QC program which

clearly establishes the authority and responsibility of those responsible for the

quality system. Persons performing quality functions shall have sufficient and

well defined authority to enforce quality requirements that initiate, identity,

recommend and provide solutions to quality problems and verify the effectiveness

of the corrective action.

CONTRACTOR'S proposed quality system shall fully satisfy all the elements of

ISO 9001, “Quality Systems - Model for Quality Assurance in Design,

Development, Production, Installation and Servicing”; ISO 9003 - “Quality

Systems - Model for Quality Assurance in Final Inspection and Test”; and ISO

9004, "Quality Management and Quality System Elements - Guidelines". The

quality systems shall provide for the planned and systematic control of all quality-

related activities performed during execution of the work. Implementation of the

system shall be in accordance with the CONTRACTOR'S Quality Manual and

Project Specific Quality Plan, which shall both together with all related/referenced

procedures be submitted to the COMPANY for review, comment and approval.

The COMPANY reserves the right to inspect materials and workmanship at all

stages of concrete production and delivery and to witness any or all tests. The

CONTRACTOR, 30 days after award, but prior to the pre-inspection meeting,

shall provide the COMPANY with a copy of the Inspection plan for review and

inclusion of any mandatory COMPANY witness points.

6 DOCUMENTATION

The Batch Plant CONTRACTOR shall submit the following in accordance with

the Vendor Drawing and Data requirements section of the Purchase Order/

Subcontract:

Overall plant layout, batch plant system description, equipment and

operational details including automation, computerization, concrete

transportation mixer truck operation and operator qualifications.

All records and reports as described in Sections 13.0 and 14.0 respectively

Batch tickets

7 BATCH PLANT

The batch plant, including storage facilities, and delivery trucks shall meet the

requirements of ASTM C94 and ACI 304R Chapters 2, 3, and 4. The batch plant,

including storage facilities, and delivery trucks shall be capable of producing

quality concrete, and shall be able to become certified in accordance with the

certification process of NRMCA QC 3. The CONTRACTOR shall be fully

responsible for the quality of the concrete, up to the discharge end of the delivery

equipment chute.

The batch plant shall include, but not be limited to:

- Full automation

- Full computerization

- Full segregation of materials

- Shaded and covered areas for materials to prevent contamination by rain,

dirt, sand, mud, air borne chlorides, dust and other contaminants

- Facilities for washing and cleaning materials with adequate drainage

- Automatic compensation for moisture in fine aggregate

- Adequate ice and chilled water plants with automatic feeding lines

- Adequate production capacity

- Back up facilities (which may be as great as 100% for certain situations)

- Ability to provide computer print out of mix design together with actual mix

- Ability to provide computer calculation and print out of actual water/cement

ratio

The CONTRACTOR shall ensure that the concrete is mixed in a fully automatic

computerized batching plant.

The mixing plant capacity shall be selected to ensure that the required maximum

production can be comfortably achieved.

The weights of fine and coarse aggregates shall be automatically adjusted to allow

for any free water contained in them. Accordingly, the amount of water to be

added shall be reduced by this amount of free water contained in the aggregates.

The quantities of all materials for concrete shall be charged to the pan by weight

(water by volume).

Admixtures that have been approved as part of the mix design shall be added by

approved automatic dosing equipment capable of feeding fixed quantities into the

mixing water before the water is charged into the mixer.

The measuring equipment shall be maintained in a clean, serviceable condition.

Mixing shall continue until uniform distribution of materials and uniformity of

consistency and color is obtained.

The CONTRACTOR shall ensure that the materials used for each batch in the

mixer do not exceed the manufacturer's rated capacity for the machine. The

machine shall be kept clean, free of any residual material after depositing each

batch of concrete and the mixer pan drum shall be washed and cleaned out

immediately following the completion of each concreting operation.

The batch plant shall be able to provide a computer printout batch ticket of the

following for each truck:

- Serial number of ticket

- Date

- Truck number

- Grade of concrete

- Amount of concrete

- Amount of cement and slag

- Information necessary to calculate total mixing water added (free water on

aggregates, water, and ice batched at plant)

- Type, brand, and amount of admixtures

- Weights of fine and coarse aggregate

- Time loaded or time of first mixing of cement and aggregates

- Reading of revolution counter at the first addition of water

- Time and reading of revolution counter at the time of the start of discharge

of the load of concrete

- Unique location identification as provided by the structure number and

concrete placement number

- Signature or initials of batch plant representative

8 MATERIALS

All materials required for the production of ready-mixed concrete shall in

accordance with Project Specification 03300, Cast in Place Concrete.

All materials must be selected from the approved sources identified in Project

Specification 03300 , Cast in Place Concrete. The CONTRACTOR shall record

on a daily basis the quantity of materials received.

Records shall be maintained to indicate:

- VENDOR’S details pertaining to cement and admixtures, and test data

of aggregates and sands

- Fully detailed data sheets showing all chemical and physical

information

- Recent test results (not older than three months)

- Details of VENDOR’S Quality Assurance System

- Details of VENDOR’S Quality Control procedures

9 MATERIAL STORAGE AND HANDLING

9.1 Cement Storage

Cement storage shall afford easy access for inspection and identification of

each shipment in accordance with test reports. It shall be used in the order

in which it is delivered to the site.

Bagged cement shall be transported to the batchplant in the VENDOR’S

original sealed bags or containers and shall be stored in a dry, weathertight,

properly ventilated covered structure, with adequate provisions for

preventing the absorption of moisture, and raised at least 150 mm off the

floor to prevent deterioration. The storage shall be large enough to allow

sufficient cement to be kept to allow continuity of work. Not more than 10

small bags or 3 “Big Bags” shall be piled one on top of the other while

stored at site. Suitable shading shall be provided to limit the temperature to

40 C.

Temperature of cement stored in bulk silos shall not exceed 75 C. No

cement shall be stored on site for more than three months.

9.2 Storage of Aggregates

The concrete plant shall at all times maintain sufficient quantities of each

type of aggregate to ensure continuity of work.

Each type and grade of aggregate shall be stored separately in bins, in such a

manner that segregation of the various size particles shall not occur. The

floors of the bins shall be of concrete or other approved material having

sufficient slope to ensure adequate drainage of aggregates before being used

for concreting.

Strict precautions shall be taken to avoid contamination of aggregates by

wind blown dust, chlorides, etc.

Suitable shading shall be provided to control the temperature and any

contaminations, especially chlorides.

Storage bins shall be emptied and cleaned at regular intervals.

10 CONCRETE DELIVERY

Delivery Trucks shall be of revolving drum type, watertight, and so constructed

that the concrete can be conveyed and discharged into the pumps at site

maintaining the uniform distribution of materials throughout the mass. The drum

shall be painted white and kept clean to ensure maximum reflectivity.

The maximum size of batch in truck mixers shall not exceed the maximum rated

capacity of the mixer as stated by the MANUFACTURER and stamped in metal

on the mixer.

On no account shall water from the concrete truck be used in the mix. Concrete

trucks shall have their water tanks completely disconnected from the drum.

Concrete temperature, when discharged in the formwork, shall not be more than

30 C. For thick elements the temperature shall be less than 24 C. Thick elements

shall be defined as any concrete member that has both plan and cross sectional

dimensions exceeding one meter, and containing a total volume exceeding six

cubic meters.

11 FACILITIES INSPECTION AND CALIBRATION

At intervals not exceeding 90 days, all scales, volumetric devices, and dispensers

of the batch plant shall be inspected and calibrated. The accuracy of the

measuring equipment shall be within 3%.

At intervals not exceeding 90 days revolution counters shall be inspected and

calibrated prior to use for hauling or mixing concrete.

At intervals not exceeding 90 days, the batch plant mixers and mixer trucks shall

be visually examined to detect changes in condition due to accumulation of

hardened concrete and examined to detect wear of blades. Mixer blades shall be

replaced when they have lost 10% of their original height in accordance with

NRMCA QC3. Restrictions shall conform to requirements of ASTM C94.

12 RECORDS

Records shall be maintained for the following:

Material certification reports received with all delivered materials (cement,

slag, aggregate, and admixtures), as described in Section 9.0. Originals of

these documents shall be sent to the testing laboratory for retention.

Copies of these documents shall be retained at the batch plant.

Required testing of materials at the batch plant as set forth in Project

Specification, DGS-CU-016, Testing Laboratory. Copies of these test

reports shall be retained at the batch plant, originals of these test reports

shall be retained by the testing laboratory.

Records of maintenance of all batch plant and delivery equipment based

on MANUFACTURER'S recommendations on a 90 day basis.

Records of all required inspections and calibrations, as described in

Section 12.0.

13 REPORTS

The CONTRACTOR shall provide a detailed weekly summary report to the

COMPANY pertaining, but not limited to, the following:

All aspects of material acquisition, transporting, storage, handling,

batching, production of concrete and transportation of the concrete to the

jobsite.

The operating aspects of plant equipment, computerization and any

problems encountered during the production of concrete.

The liaison aspects of CONTRACTOR’S work with the mix design

specialist and the testing laboratory.

Deviations in concrete mix production from the approved mix design and

documentation.

END OF SECTION