Вы находитесь на странице: 1из 38

--

DOC. NO. KOC-C-026

Page 1 of 38

REV. 1

KUWAIT OIL COMPANY (K.S.C.).

STANDARDS PUBLICATION

KOCSTANDARD
FOR
STORAGE TANK FOUNDATION
DOC. NO. KOC-C-026

STANDARDS DIVISION

KOC STANDARD
FOR
STORAGE TANK FOUNDATION
DOC. NO. KOC-C-026
-

(FORMERLY 0 1 5 SH -1001)

ISSUING AUTHORITY:

STANDARDS DIVISION

DOC. NO. KOC-C-026

Page 3 of 38

REV. 1

TABLE OF CONTENTS
PAGE NO.
FOREWORD
SCOPE
APPLICATION
TERMINOLOGY
REFERENCE STANDARDS AND CODES
ENVIORNMENTAL CONDITIONS
HEALTH, SAFETY AND ENVIRONMENT
SITE & SUB-SURFACE INFORMATION
TECHNICAL REQUIREMENTS
FOUNDATION DESIGN
MATERIAL REQUIREMENTS
CONSTRUCTION REQUIREMENTS
EARTH FOUNDATION WlTH CONCRETE RlNG WALL
EARTH FOUNDATION WITHOUT CONCRETE RlNG WALL
REPAIR OF DEFECTS 1 DAMAGES
INSPECTION AND TESTING
QUALITY ASSURANCE
DOCUMENTATION
APPENDICES
APPENDIX-I :

WP. EARTH FOUNDATION OF TANK


WlTH CONCRETE RlNG WALL

APPENDIX-II : TYP. EARTH FOUNDATION OF TANK


WlTH CONCRETE RlNG WALL
( WITH EMBEDDED C. P SYSTEM )

DOC. NO. KOC-C-026

Page 4 of 38

APPENDIX-Ill : TYP. EARTH FOUNDATION OF TANK


WITHOUT CONCRETE WALL RING
APPENDIX-IV : SITE RECORD FOR FOUNDATION WORK

REV. 1

FOREWORD
This document " KOC Standard for Storage Tank Foundation " is intended to address the need for
consistent and practical requirements for design, material selection and construction of a sound
foundation with a view to maintaining the integrity and service life of field erected storage tanks on
grade.
The types of foundation addressed in this Standard are limited to earth foundations with or without
concrete ring walls which are generally used for aboveground, vertical storage tanks in KOC.
Smaller tanks on concrete foundations or on elevated framed structures are intended to be covered
by the established design procedures used in the industries in accordance with International 1
National standards (BS, ACI, AlSC etc.).
This Standard has been approved by the Standards Technical Committee and Standards Division
for use throughout the corporate engineering and operational functions of Kuwait Oil Company.
This Standard sets out to achieve the following objectives :a)

To establish the basic technical requirements pertaining to the design, material selection and
construction of foundations for aboveground, vertical steel storage tanks.

b)

To provide general technical guidance for developing project specifications in order to


achieve reliability, quality and safety in an economical manner.

C)

To set out clear requirements to monitor compliance in design, material and construction of
tank foundations with a contract.

d)

To maintain the KOC requirements of safety and environmental protection established by


KOC regulations and procedures.

Feedback as well as any comments or suggestions derived from the application of this Standard at
any stage of conceptual design, engineering, purchase or field construction are invited and should
be directed to :
Supdt. Standards Division
(Chairman, Standards Technical Committee)
Engineering Group, K.0.C
P.O.Box- 9758, Ahmadi 61008,
State of Kuwait
The preparation of this Standard is acknowledged to the Task Force (TF-CIVJO1) comprising of the
following members:Mr. S. Kumar
Mr. Javaid Masood
Mr. Khalid Al-Sayed

(Standards Div.)
(Engg. Design Div.)
(Maint. Project Div.)

Team Leader /Author


Member / Author (Part)
Member

Page 6 of 38

REV. 1

SCOPE

This Standard specifies the minimum basic requirements for the design, materials and
workmanship related to the following types of Foundation for aboveground, vertical,
sloping bottomed Steel Storage Tanks at the KOC facilities within Kuwait :- a)

Earth Foundation with Concrete Ring Wall

b)

Earth Foundation without Concrete Ring Wall.

This Standard covers the extent of work as described herein and includes, but not
limited to, design, excavation, reinforced concrete construction, backfilling, compaction
of fill materials, surface protective layers, inspection, testing and quality control
involved in the works.
This Standard does not address the other aspects of Site work such as demolition, site
clearance, borrow pit, excavation, filling, hauling, compaction, disposal etc. which are
" Site
specifically covered under KOC standard for materials and workmanship
Preparation and Earthworks " ( KOC-C-005 ).

However, this Standard does not specify the actual extent of foundation work which
shall be in compliance with the relevant contractual requirements specified in Scope of
Work , Technical Specifications and Drawings.
APPLICATION

The design, materials, construction and testing for any work related to the specified
type of storage tank foundation shall conform to the requirements of this Standard and
the reference standards / codes mentioned herein.
The allowable soil loading and the exact type of subsurface construction to be used
must be decided for each tank or group of tanks after careful consideration of design
and ground conditions prior to the application of this Standard.
Any exceptions or deviations ftom this Standard, along with their merits and
justification, shall be brought to the attention of KOC Controlling Department for their
review, consideration and amendment by Standards Division ( if required ).
Compliance with this KOC Standard does not of itself confer immunity from legal or
statutory obligations.
TERMINOLOGY

For the purposes of this Standard, the following definiCans apply.


3.1.1

designer
person or persons from KOC or firm / company approved'by KOC who are undertaking
the design of the tank foundation work.

contractor
person or persons, firm or company, approved by KOC, who are undertaking the
construction work covered by this Standard.
gatch
local name of a type of calcareous soil.
NOTE This, as a fine to medium well graded granular material, exhibits good cementing
properties under compaction. It is widely used in Kuwait as a major filling material.

suitable material
all materials such as gravels, graded sands, silt and non-plastic clay.
NOTE Sizes nor larger than 50 mm for fill / backfill in accordance with KOC Standard KOC-C005 as to compaction and soil classification.

unsuitable material
perishable or combustible material, peat, muck, slurry, rocks or any buried debris,
highly sensitive plastic clay, expansive clay.
optimum moisture content ( OMC 1
moisture content expressed as a percentage of dry mass at which a specified amount
of compaction will produce the maximum dry density.
compaction
process of packing soil particles more closely together by rolling or by other
mechanical means, thus increasing the dry density of the soil as a consequence of
removal of air from the voids between particles.
asphalt cement

a fluxed or unfluxed asphalt specially prepared as to quality and consistency for direct
use in the construction of bituminous pavements, and having a penetration at 25C
(77F) varying between 5 to 300, under a load of 100 grams applied for 5 seconds.
penetration grade
consistency of a bituminous material expressed as the distance in tenths of a
millimetre (0.1 mm) that a standard needle penetrates vertically a sample of the
material under specified conditions of loading, time and temperature.
NOTE For exemple, ssphelt grade 70 expresses ?he consistency when tested at 25C, a
standard needle weighing 8 total of 100 grams penetnrtes 8 material sample in 5 seconds a
maximum distance of 7 mm or 70 tenths of a mm.

DOC. NO. KOC-C-026

Page 8 of 38

REV. 1

Abbreviations
KOC

Kuwait Oil Company ( K.S.C. 1

HSE

Health, Safety and Environment

OFT

Dry Film Thickness

--

REFERENCE STANDARDS AND CODES


Conflicts
In the event of conflict between this Standard and the standards / codes referenced
herein, or other purchase or contractual requirements, the most stringent requirement
shall apply.
List of Standards and Codes
The latest edition of the following standards, codes and specifications shall apply :
Standards and Codes
ACI 315

Details and Detailing of Concrete Reinforcement

ACI 318M

Building Code Requirements for Reinforced Concrete

API 650

Welded Steel Tanks for Oil Storage

ASCE

Guidelines for Seismic Evaluation and Design of Petrochemical


Facilities by Task Committee

ASTM A61 5

Specification for Deformed


Concrete Reinforcement

ASTM C33

Specification for Concrete Aggregates

ASTM C39

Test Method for Compressive Strength of Cylindrical Concrete


Specimens

ASTM C88

Test Method for Soundness of Aggregates by Use of Sodium


Sulphate or Magnesium Sulphate

ASTM C l s l

Test Method for Resistance to Degradation of Small-Size Coarse


Aggregate b y Abrasion and Impact in the Los Angeles Machine

ASTM C136

Method of Sieve Analysis of Fine and Coarse Aggregates

ASTM C150

Specification for Portland Cement

ASTM D5

Test Method for Penetration of Bituminous Materials

ASTM 0242

Specification for Mineral Filler for Bituminous Paving Mixtures

and

Plain

Billet Steel Bars for

DOC.NO. KOC-C-026

Page 9 of 38

REV. 1

ASTM D546

Test Method for Sieve Analysis of Mineral Filler for Road and Paving
Materials

ASTM D692

Specification for Coarse Aggregate for Bituminous Paving Mixers

ASTM D946

Specification for Penetration-Graded Asphalt Cement for Use in


Pavement Construction

ASTM D 1073

Specification for Fine Aggregate for Bituminous Paving Mixtures

ASTM Dl075

Test Method for Effect of Water on Compressive Strength of


Compacted Bituminous Mixtures

ASTM D1 556

Test Method for Density of Soil In Place by the Sand Cone Method

ASTM D1 557

Test Method for Laboratory Compaction Characteristics of Soil Using


Modified Effort

ASTM Dl559

Test Method for Resistance to Plastic Flow of Bituminous Mixtures


Using Marshall Apparatus

ASTM 01751

Specification for Preformed Expansion Joint Filler for Concrete Paving


and Structural Construction ( Non-extruding and Resilient Bituminous
Types )

ASTM 021 72

Test Methods for Quantitative


Mixtures

ASTM D35 1 5

Specification for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

BS 410

Specification for Test Sieve

BS 812

Methods of Testing Aggregates

BS 882

Specification of Aggregates from Natural Sources for Concrete

BS 1377

Methods of Test for Soils for Civil Engineering Purposes

BS 1881

Testing of Concrete

BS 2654

Specification for Manufacture of Vertical Steel Welded NonRefrigerated Storage Tanks with Butt-Welded Shells for the Petroleum
Industry

BS 4449

Specification for Carbon Steel Bars for the Reinforcement

BS 4466

Specification for Scheduling, Dimensioning, Bending and Cutting of

BS 5075
(Part 1)

Concrete Admixtures Specification for Accelerating Admixtures,


Retarding Admixtures and Water Reducing Admixtures

BS 8004

Code of Practice for Foundations

Extraction of Bituminous Paving

BS 8110
(Part 1)

Structural Use Concrete Code of Practice for Design and


Construction

KOC Standards

5.0

KOC-C-001

KOC Standard for Basic Civil Engineering Design Data

KOC-C-005

KOC Standard for Materials and Workmanship Site Preparation and


Earthworks

KOC-C-006

KOC Standard for Materials and Workmanship Concrete Works

KOC-C-033

KOC Standard for Materials and Workmanship Bund Wall for Storage
Tanks

KOC-G-007

KOC Standard for Basic Design Data

KOC-1-026

KOC Recommended Practice for External Cathodic Protection for New


Steel Tank Bottoms

KOC-MV-007

KOC Standard for Field Erected Storage Tanks

ENVIRONMENTAL CONDITIONS
The environmental conditions in Kuwait are severe. Refer to KOC Standard for Basic
Design Data (KOC-G-007) which provides the detailed design information regarding the
environmental, site and utility supply conditions prevailing throughout the KOC facilities.

6.0

HEALTH, SAFETY AND ENVIRONMENT

6.1

The contractor shall employ the necessary health and safety procedures to protect
personnel and surrounding environment during Site preparation end other on-site field
works.

6.2

All relevant safety requirements of the KOC Fire & Safety Regulations and the KOC
HSE policy shall be adhered t o while performing the works within KOC areas.

DOC. NO. KOC-C-026

Page 11 of 38

REV. 1

SITE 81SUB-SURFACE INFORMATION


General
The topography of a Site shall be assessed from the area contour maps o n the basis of
a recently conducted topographical survey of the actual tank Site and its adjoining
areas.
For ease of reference, the Site formation level shall generally be considered as Site
grade level equal to EL100.00 m. The relationship of this level with the Mina Ahmadi
Construction Datum (MACD) shall be established by the designer /contractor and
shown on all major layout drawings.
The Site co-ordinates ( Northing & Easting ) shall be established in Universal Transverse
Mercator (UTM) Grid, Zone 38, World Geodetic System (WGS) at the time of
topographical survey and shall be verified further by the contractor prior to
commencement of any work.
Sub-surface Conditions

KOC shall conduct a geotechnical investigation at any tank site to determine the
subsurface conditions and its suitability for the proposed tank sizes. The investigation
should address, among other information, the bearing capacity of the soil, anticipated
settlements - immediate, long-term and differential settlements.
However, as the settlement calculations are of limited accuracy, the tank manufacturer
I contractor shall use the information and recommendations from this KOC report as
guidance only and is responsible to make his own interpretations about the site
conditions by carrying out any additional or supplementary geotechnical exploration, if
deemed to be necessary. Any additional exploration shall be conducted with the
minimum three ( 3 boreholes at 120' under the tank area(s).
The subgrade must be capable of supporting the load of tank and its contents. The
total and peripheral differential settlements shall be assessed not to strain the
connecting piping or produce gauging inaccuracies and shall be within the acceptable
tolerances for the tank shell and bottom.
In case subgrade supporting the foundation is weak and inadequate to carry the load of
the filled tank without excessive uniform settlement (150 mm or more), one or more of
the following special measures should be considered for improving the support
conditions :a)

Removal and replacement of unsuitable material below the foundation by the


suitable compacted fill material.

b)

Densification of soft or ioose materials by vibroflotation, dynamic


compaction or preloading with an overburden of other material.

C)

Sub-soil drainage by stone columns or sand drains with or without


preloading.

d)

Stabilization by chemical or grout injection methods.

NOTE Spsclbl technques of grorrndh,prowmant nslatd to items (bj to (dl above are outside the
mope of this S t a m h i and dm1& dsslY lbpuatdy.

TECHNICAL REQUIREMENTS
..

..

General
The tank foundation shall be designed and installed satisfying the requirements as laid
down in this KOC Standard and API 650 for the safe and satisfactory performance of
the underlying supporting soil and the foundation system.
Normally, the tank foundations should not be located in Sites on swampy or filled
ground, where layers of soft and compressible materials (muck, organic or plastic clay)
are below the surface in order to avoid excessive long term settlement problems.

The ultimate bearing capacity of tank foundation shall be determined by a


comprehensive stability analysis. The following ranges for factors of safety should be
considered for use in foundation design criteria for determining the allowable soil
bearing pressures :a)

From 2.0 to 3.0 against ultimate bearing failure for normal operating conditions.

b)

from 1.5 to 2.25 against ultimate bearing failure during hydrostatic testing.

C)

from 1.5 to 2.25 against ultimate bearing failure for normal operating condition
plus the maximum effect of wind or seismic (if applicable) loads.

However, depending on the actual sub-surface conditions, KOC may use factor of
safety outside the above ranges in compliance with the recommendations of the
geotechnical specialist.

The permissible settlements 9.g. the maximum allowable design limits for the
settlement of the foundation shall be agreed between KOC and the tank manufacturer
for the uniform (total) and differential settlement across the bottom and the periphery of
the tank.
Considerations affecting the limits of permissible settlement should be given to the
following :a)

The dimensions and aspect ratio (HID) of the tank.

b)

Tank types e.g open roof, fixed roof or floating roof (pontoon type).

C)

Effect of cyclic loading on the amount of iong-term ( total ) settlement.

DOC. NO. KOC-C-026

Page 13 of 38

REV. 1

d)

Type of underlying soil (slow draining, pockets of weak soils).

e)

The difference in settlement between the periphery and the centre.

The following permissible range of predicted settlements for tank foundations should be
considered as guidance only:
a)

50 mm for uniform (immediate) settlement or 1.5 mm per metre ( 112 inch per
30 ft )for differential settlement during hydrostatic testing of the tank.

- 2.8 mm

b)

Maximum differential settlement for floating roof tank not to exceed


per metre ( 1 inch per 30 ft ) of circumference.

c)

Maximum differential settlement for fixed roof tank not to exceed - 50 to 75 mm


from edge to centre of foundation or 4.0 mm per metre ( 1.5 inch per 30 ft ) of
circumference.

d)

100 - 150 mm for long-term uniform (total) settlement.

e)

In case of excessive settlement ( > 150 mm 1, special measures shall be taken


to strengthen the supporting soil in conformity with dause 7.2.4 of this
Standard.

During hydrostatic and leak testing of tanks in accordance with dause 11.7.5 of KOCMV-007, adequate level of careful observations and monitoring of foundation behaviour
shall be taken to prevent any unexpected and abnormal soil movement which may tend
to exceed the specified limit of foundation settlement in the testing procedure.
Subgrade Protection
The subgrade protection from leakage of tank contents ( hydrocarbon, chemicals etc. )
shall be decided by the KOC Controlling Department considering the presence of ground
water at shallow depth, hazards of contaminated soil, effectiveness of cathodic
protection system and cost involved in providing the system.
However, in view of increasing consciousness of environmental and safety implications .
due to leakage of tank contents into the containment space below the tank bottom,
API 650 recommends under Appendix I to provide secondary containment barrier such
as flexible membrane liner or other suitable system which is not mandatory.

Tank Grades

I%

The grade or surface on which a tank bottom will rest should be constructed at least
300 mm above the surrounding ground surface. However, any appreciable settlement
of subgrade, when predicted at the design stage, shall be compensated by raising the
tank bottom elevation.
In case of oil storage tanks, if the membrane liner within the tank pad is recommended
for environmental protection for any oil leakage, the tank grades shall be increased, as
required, to accommodate the cathodic protection system below the tank bottoms for
the prevention of corrosion.

.. DOC. NO. KOC-C-026

8.6.1

8.6.2

Page 14 of 38

REV. 1

Based on the adequacy of subsurface conditions e.g. the load bearing capacity of soil
and permissible settlements, the types of tank foundations should be considered for
tank sizes (diameter & height) as below unless otherwise specified:a)

Earth foundation with concrete ring wall for tanks


( Diameter > 35 m & Height 2 15 m 1

b)

Earth foundation without concrete ring wall for tanks


( Diameter < 35 m & Height < 15 m

Notwithstanding above, in some situation, the foundations of smaller tanks may be


installed with concrete ring wall with the following considerations over the foundation
without ring wall :
a)

It provides better distribution of the concentrated load of the shell to produce a


more nearly uniform soil loading under the tank.

b)

It provides a level, solid starting plane for construction of the shell.

c)

It provides a better means of levelling the tank grade and is capable of


preserving its contour during construction.

d)

It retains the fill under the tank bottom and prevents the loss of material from
erosion.

e)

It acts to minimise moisture under the tank.

However, foundation without concrete ring wall performs well in areas with good soils;
and is inexpensive compared to that with concrete ring wall.
9.0

FOUNDATION DESIGN

The tank foundations shall be designed considering the following conditions in


accordance with the design loads specified in data sheet(s) of KOC Standard for " Field
Erected Storage Tanks " (KOC-MV-007).
9.1.1

Vertical Loading
Dead weights of tank including all attachments end appurtenances plus the full weight
of stored product or water whichever is greater shall be accounted.

9.1.2

Horizontal Loading

tiorizontal loads shall be taken due t o wind forces on tank shell, roof and its
attachments as well as liquid contents ( empty or full ) at the tank bottom. Seismic
condition (if applicable) shall not be combined with wind condition.

1
1

1
1

1
I

Sliding Stability
9-1-3
Sliding stability of tank foundation shall be checked due to horizontal loads as mentioned above in clause 9.1.2 against soil friction neglecting passive earth pressure.
A minimum safety factor of 1.5 shall be taken against sliding.
Uplift IOverturning IAnchorage
9-1.4

a)

The requirement of tank anchorage due to uplift shall be recommended by the


tank manufacturer against overturning instability for wind or seismic conditions
in accordance with relevant clauses of API 650 or BS 2654.

b)

However, additional vertical load from the overturning moment due to wind or
seismic forces shall be considered on the foundation for any unanchored or
anchored tanks.

C)

If the anchors are necessary, the embedment strength of anchor bolts in the
foundation shall be provided to develop the minimum yield strength of the
anchor. Hooked anchor or end plates may be used to resist pullout.

Earth Foundation With Concrete Ring Wall

9.2
General
9.2.1
a)

The foundation shall consist of a reinforced concrete (RC) ring wall directly
supporting the tank shell and a compacted earth pad below the tank bottom as
a inner core.

b)

The average unit soil loading under the ring wall shall be designed within the
allowable soil bearing capacity and approximately the same as under the
confined earth at the same depth to minimise the chance of differential
settlements.

Concrete Ring Wall

9.2.2
a)

The ring wall shall be designed to fully withstand any stresses ( hoop, uplift,
bearing, bending, shear, torsion and temperature etc. ) induced by the tank
and its contents under the most severe loading conditions (static, dynamic and
cyclic). The most critical load combinations including wind or seismic effects
and differential settlements that induce the worst stresses within the concrete
should be considered.

b)

The design of concrete shall conform to ACI 318 or BS 81 10.

C)

The ring wall shall not be less than 300 mm thick and its bottom shall be
founded within the specified bearing strata but not less than 900 mm for tank
dia. 2 35m and 600 mm for tank dia. < 35m below the finished grade or natural
ground level whichever is lower, subject to the actual site conditions.

d)

The centre line diameter of the ring wall shall be equal to the nominal diameter of
the tank. However, the centre line may vary, in case it is required to provide
anchor bolts or to satisfy soil bearing limits for excessive uplift forces.

DOC. NO. KOC-C-026

Page 1 6 of 38

REV. 1

The ring wall shall be reinforced to resist direct hoop tension resulting from the
lateral earth pressure on the ring wall inner face. The lateral earth pressure shall
be taken at least 50% of the vertical pressure due to liquid contents and soil
weight. If granular backfill is used, a lateral earth pressure co-efficient of 30%
may be used.
The ring wall shall be reinforced to resist the bending moment resulting from the
uniform moment load which shall account for the eccentricities of the applied
shell and pressure loads relative to the centroid of the soil pressures due to the
liquid pressures on the horizontal projection of the ring wall inside the shell.
Adequate reinforcements shall be provided to resist the bending and torsional
moments from lateral and wind or seismic (if applicable) loads.
Reinforcement provided for resisting direct hoop tension for temperature changes
and shrinkage shall in no case be less than 0.25 % of the vertical cross-sectional
area of the ring wall.
The minimum vertical reinforcements for temperature changes and shrinkage
shall be 0.15 % of the horizontal cross-sectional area of the ring wall.
Reinforcements shall be provided on both faces of ring wall.
Corner chamfers (50 mm x 50 mm) shall be provided to the outside and inside
faces of top of concrete ring wall.
Footing shall be provided below the ring wall when the width of the wall exceeds
450 mm.
9.2.3

Earth Pad Below Tank Bottom


a)

Earth pad within the confined area of ring wall below the tank bottom shall be
composed of compacted gatch in accordance with KOC Standard KOC-C-005
and shall conform to the tank grade level specified in dause 8.5 of this Standard.

b)

The compacted gatch shall be cambered from the tank centre to the tank shell
at e minimum slope of 1:I20 for drainage and shall conform to the tank bottom
slope specified in KOC-MV-007.

c)

It shall then be overlaid with the successive layers es follows :

i.

a stable and permeable layer of 100 mm thick smdqravei mix with


gradation as per dause 10.2.1 of this Standard.

ii. a final layer of dean washed sand as bearing surface of tank bottom with
gradation as per clause 10.2.3 of this Standard. The thickness shall vary
from minimum 1OOmm ( for non-embedded CP system ) to maximum
400mm ( for embedded CP system 1.

d)

The finished level shall be smooth and free from any irregularities. Details related
to the tank bottom shall be informed to the tank manufacturer for the ease of
fabrication.

9.2.4

Surface Protective Layers


The surface protective layers shall be provided in conformity with the following
materials :-

9.2.5

9.2.6

a)

The top surface of concrete ring wall beneath the bottom annular plates of tank
shell shall be covered with a 25 mm thick asphalt impregnated board in
conformity with ASTM Dl751 or with 25 mm thick non-shrink grout of a
proprietary brand as approved by KOC.

b)

The outside area of the ring wall shall be covered with a minimum depth of
225 mm compacted gat&
and finished with 75 mm thick protective
layer of asphaltic concrete as specified in clause 10.3 of this Standard to form
a firm shoulder around the tank periphery. Shoulder shall be at least 900 mm
wide with gentle slope of 5% and then have a slope of 1:l-112 towards
the graded surface.

Cathodic Protection
a)

For cathodic protection system embedded below the tank bottom, the total
depth given in 9.2.4 (b) shall be increased to minimum 750 mm which shall
be verified for adequacy by the designer I contractor.

b)

Permanent reference electrodes to monitor the effectiveness of CP system shall


be installed within the foundation pad below the tank bottom in accordance
with clause 8.1 0 of KOC-L-026.

Leak Detection
To detect any leakage from the tank bottom, 75 mm dia. PVC pipes or equal shall be
provided at a spacing not more than 5.0 m c/c around periphery of the foundation and
shall be connected to a covered collection pit at suitable location. Plastic mesh screen
shall be fixed inside the open end of the pipe.

9.2.7

Membrane Liners (Optional)


Membrane liners, if recommended as per clause 8.4 of this Standard, should be
flexible, chemically resistant and suitable to the subgrade soil. Minimum thickness shall
be 1000 microns (40 mils) for polyethylene sheet liner.

9.2.8

Refer to Appendix-l for details of earth foundation with concrete ring wall and
Appendix4 for details of tank foundation with embedded C.P system.

DOC.NO. KOC-C-026

Page 18 of 38

REV. 1

Earth Foundation Without Concrete Ring Wall


General
a)

The foundation shall consist of a compacted crushed stone ring wall to support
directly the tank shell for better distribution of the concentrated load from the
shell and produce more nearly uniform soil loading under the tank.
'

b)

The earth pad below the tank bottom as a inner core shall be made of layers of
well compacted fill of gatch, overlaid with a compacted 100 mm thick sand gravel layer on top of it and finished with a final layer of 150 mm dean washed
sand cushion as bearing surface of tank bottoms

Tank shell Ring


a)

The ring beneath the tank perimeter shall be 1800 mm (6 f t ) wide with tank shell
as centre end shall have slopes of 1: 1-1I2 on both inside and outside. Bottom
shall be founded within the specified bearing strata but not less than 900 mm
below the finished grade or natural ground level whichever is lower, subject to
the actual site conditions.

b)

The ring shall be composed of compacted 25 mm graded crushed stone or


gravel with screenings and dean sand.

Earth Pad Below Tank Bottom


The earth pad below the tank bottom shall be provided with the same materials as
detailed in clause 9.2.3 of this Standard.
Surface Protective Layers
a)

The outside area of the ring wall shall be finished with a 75 mm thick protective
layer of asphaltic concrete as specified in clause 10.3 of this Standard to form a
firm shoulder around the tank periphery. This protective layer shall extend from
the outer toe of the slope to at least 900 mm inside of the tank perimeter.

b)

25 mm thick asphalt impregnated board in conformity with ASTM D l 751 or


25 mm thick non-shrink grout of a proprietary brand as approved by KOC shall
be provided below the bottom annular plate of the tank shell t o cover the full
width of the plate.

Similar details shall be followed as given in clauses from 9.2.5 to 9.2.7 of this
Standard for CP system embedded below the tank bottoms, pipes for leak detection
end membrane liners.
Refer to Appendix-Ill for details of earth foundation wittrout concrete ring wall.

DOC. NO. KOC-C-026

MATERIAL REQUIREMENTS
Fill Material
Gatch t o be used for construction of storage tank foundation(s) and grading of outer
areas over the general formation level indicated on the drawings / specifications shall
be borrowed from KOC approved borrow pits and shall comply with all the
requirements specified in clause 7.0 & 8.0 of KOC Standard KOC-C-005.
Materials that do not conform t o the requirements of clause 7.2 of KOC Standard
KOC-C-005 shall be considered unacceptable, removed from the Site and replaced
with gatch or approved suitable soil in accordance with clause 7.0 of KOC Standard
KOC-C-005.
Sand-Gravel Mix
The sand-gravel layer shall consist of crushed mineral aggregates or natural mineral
aggregates in conformity with the gradation of coarse t o fine percentages given in
Table I.
Table I : Particle Size Grading

Coarse Aggregate
a)

Coarse aggregate retained on the sieve size 4.75 m m ( No. 4 ) shall be made of
crushed stone, crushed gravel or natural gravel. The maximum size of coarse
aggregate shall be 25 mm.

b)

Coarse aggregate shall be hard, durable and free from organic matter, silt, clay
and any other deleterious materials.

c)

Coarse aggregate shall conform t o the various requirements, when tested, in


accordance with ASTM C131 and BS 812; and when subjected t o 5 cycles of
the soundness test as per ASTM C88 shall have a weighted loss not more than
5 % when magnesium sulphate is used.

f i n e Aggregate
a)

.-

Fine aggregate passing the sieve size 4.75 m m ( No. 4 ) shall consist of graded
natural sand and 1 or crushed sand conforming t o BS 882, Table 4,-Grading C or
M.

DOC. NO. KOC-C-026

Page 20 of 38

REV. 1

b)

Fine aggregate shall be clean, free from organic matter, silt, clay and other
detrimental and deleterious materials. The ratio of fine aggregate passing thesieve size 7 5 pm ( No. 200 ) shall not be more than 213 of the amount passing
the sieve size 4.75 mm ( No. 4 1.

C)

Fine aggregate shall be washed as necessary, w h k tested, t o comply with the


requirements in accordance with BS 812 and in addition,. shall satisfy the
following chemical analysis :

d)

I.

Sulphates as SO3

ii.

Chlorides as CI

< 250 ppm (0.025%)


< 50 ppm (0.005%)

The material passing the 425 pm ( No. 40 ) sieve shall have a liquid limit less
than 35 and a plasticity index not more than 6.

Wherever the gradation does not conform to the limits specified, the layer shall be
scarified, removed andlor reworked as directed by KOC t o provide the material mix
within the above limits.
As~halticConcrete
a) The asphaltic concrete shall be composed of hot mixing of crushed mineral
aggregate, natural sand, mineral filler of limestone cement and asphalt cement in
conformity with clauses 10.3.2, 10.3.3, 10.3.4 and 10.3.5 of this Standard.
b)

The asphaltic concrete mix should be selected from the recommended grading
requirements for coarse and fine aggregate from ASTM D l 073 with mineral filler
and asphalt cement as binder in the approximate quantities by weight of total
aggregate as follows:

I.

Mineral Filler

ii.

Asphalt Cement 7 % f 0.5 %

5 %f 1%

Coarse Aggregate
a)

Coarse aggregate retained on the No. 8 (2.36 mm) sieve shall consist of crushed
natural stone and gravel. Coarse particles shall be cubic and angular in shape
and shall not be thin, flaky or elongated.

b)

Coarse aggregate shall be clean and free from organic matter, sand, silt, clay and
clay and other detrimental or deleterious matter and shall have particles not less
than 8 0 % by weight with at least one fractured face.

C)

Coarse aggregate shall be sound, when the particles subjected t o the five ( 5 )
cycles of the soundness test in accordance with ASTM C88, shall have the
weighted loss not more than 12 % when sodium sulphate is used or 18 % when
magnesium sulphate is used.

DOC. NO. KOC-C-026


1 0.3.3

Page 21 of 38

REV. 1

Fine Aggregate
a)

Fine aggregate passing the No. 8 ( 2.36 mm ) sieve shall consist of graded natural
sand andlor crushed sand conforming to ASTM Dl 073 Grading 2.

b) Sand shall be clean, free from organic matter, silt, clay and other injurious or
deleterious materials and shall be washed as necessary. Sand shall be free from
the chemicals such as sulphate and chloride and shall satisfy the requirements in
accordance with BS 812.
C)

Fine aggregate, when subjected to the five ( 5 cycles of the soundness test in
accordance with ASTM C88, shall have weighted loss not more than 15% when
sodium sulphate is used or 20% when magnesium sulphate is used.

d) The fraction of fine aggregate passing the No. 40 ( 425 pm sieve shall have a
plasticity index not more than 4;and the fraction passing the No 200 ( 75 pm )
sieve shall not have fines more than 5 % by weight.

1 0.3.4

Mineral Filler
a)

Mineral filler shall consist of finely ground particles of limestone cement in


accordance with ASTM D242 and shall be thoroughly dry and free from lumps.

b) Mineral filler shall be tested to comply with ASTM D546 for sieve analysis and
shall be graded per ASTM D242 within the limits given in Table II :Table II : Physical Requirements of Mineral Filler

c)

1 0.3.5

Cement to be used as mineral filler shall meet the requirements of Type I, II, or V
in accordance with ASTM C150.

Asphalt Cement
a) Asphalt cement shall be 60-70 Penetration Grade and shall satisfy the
requirements in accordance with ASTM D946 8s given in Table Ill :-

DOC. NO. KOC-C-026

Page 22 of 38

REV. 1

m e Ill : Requirements for Asphaft Cemnt (60-70 Grade)

1 thin-film oven test

Note 1-

b)

N ductility at 2 5 "1: ( 77 51 is less than 100cm, material will be accepted 17


ductility st 15.5 S: ( 60 F 1 is lOOcm at the pull rete of 6 cm / min.

Asphalt cement shall be uniform in character and shall not foam when heated to
175 O C ( 347 O F 1.

The selected materials of in-situ concrete for ring wall construction shall comply with
the following clauses 10.4.2 to 10.4.7.
Cement
a)

Unless otherwise mentioned, Portland Cement conforming to ASTM C150


Type II or V shall be used.

b)

Only a single brand of cement shall be used throughout the work; change of brand
shall be subject to KOC approval.

Aggregates
Aggregates shall comply with BS 882 or ASTM C33 and conform to the following :a)

It shall be dean, free from oil, grease or any contamination; hard, sound and
mixture of well graded coarse and fine partides.

b) All partides shall pass s 20 mm ( 314 in ) BS 410 sieve sue and the fineness
modulus of fine aggregates shall be neither less than 2.3 nor more than 3.1.
li'

c)

Fine aggregates shall be free from organic / inorganic impurities and shall not
contain other deleterious substances more than 5 % by weight.

C) The aggregates for in-situ concrete shall be composed of maximum 20mm singlesized coarse aggregates in accordance with Table 3 of BS 882 with fine
aggregates conforming to Grading C or M of Table 4 of BS 882.

e)

All aggregates shall meet the testing requirements in accordance with BS 812,
ASTM C88 and ASTM C131.

Reinforcement
Reinforcement shall be new, uncoated, free from rust, scale, salts or any deleterious
material which can reduce or destroy bond with the concrete. It shall comply with the
specified grades as follows:a)

High yield deformed bars to be used as main reinforcements shall have the
minimum specified characteristic strength of 460 N / mm2 in accordance with BS
4449 or Grade 60 with a specified yield of 414 N / mm2 in accordance with
ASTM A61 5.

b)

Plain, round mild steel bars to be used as stirrups, ties and links shall have the
minimum specified characteristic strength of 250 N / mm2 in accordance with
BS 4449 or Grade 40 with a specified yield of 414 N / mm2 in accordance with
ASTM A61 5.

C)

Lap reinforcement splices shall be used to develop full strength complying with
ACI 31 5 or BS 4466.

Admixtures
Normal water reducing admixtures as defined in BS 5075 shall be added to in-situ
concrete to maintain sufficient workability at the minimum water / cement ratio. The
type of admixture shall be subject to KOC approval and the dosage and mixing shall be
strictly in compliance with the instructions of the manufacturer. Under no
Icircumstances, shall admixtures containing chlorides or other corrosive agents be used.
Water
Only clean and clear water from potable supply system shall be used.
Concrete Mix
The in-situ concrete shall comply with BS 81 10 and shall have a minimum cement
content of 370 kg/m3for structural concrete. The minimum characteristic strength of
structural concrete ( Grade 20 1 at 28 days shall be 20 ~ / m m The
~ . minimum concrete
grade 15 shall be used for blinding concrete.

Supply end Storage of Materials


All materials shall be adequately protected against any contamination and damages and
from the weather during 'loading, transportation, unloading and storage. Bagged
materials shall not be set directly on the ground and shall be kept under cover and dry.
Materials that do not conform to the requirements of this Standard and the reference
standards / codes shall be rejected and removed immediately from the place of work as
directed by KOC.

DOC. NO. KOC-C-026

Page 24 of 38

REV. 1

CONSTRUCTION REQUIREMENTS

The contractor shall provide all materials in conformity with dause 10.0 of this
Standard ; equipment, tool$ and experienced manpower necessary for carrying out the
work.
All equipment, tools and machines used by the contractor in the proper execution of the
work shall be subject to KOC approval and shall be maintained in good conditions till
the completion of the work.

The earthworks shall commence in accordance with the requirements specified in


clause 10.0 of KOC Standard for Materials and Workmanship " Site Preparation and
Earthwork " ( KOC-C-005 1.

Weather Limitations
Concrete shall neither be mixed and placed when the ambient temperature is below 2
OC (35 OF) nor when the air temperature in the shade is 40 OC (104 OF) or above. No
concrete shall be placed during high sand storms or rain unless adequately protected or
unless otherwise directed by KOC. The temperature of the concrete when placed shall
not exceed 32 OC.
Asphaltic concrete shall be installed when the atmospheric temperature in the shade is
10 OC (50 OF) or above. No work shall continue when the temperature is below 2 OC
(35 OF) or when there is occurrence of continuous high winds, fog or rain other than
very light sprinkle.
EARTH FOUNDATION WITH CONCRETE RING WALL

The Site for the tank foundation(s1 shall be prepared, cut and / or filled (as the case
may be) and compacted I proof rolled with at least four (41passes of a 10-ton vibratory
roller to the design formation levels as indicated in the Contract specifications or
approved construction drawings in conformity with dause 11.0 of KOC Standard KOCC-005.
Any soil having susceptible characteristics encountered during the progress of the
excavetion below the foundation or formation level shall be tested in accordance
with dause 14.2 of KOC Standard KOC-C-005. If found to be unsuitable as base
for tank foundations, it shall be excavated and removed from the Site to the KOC
approved dump yard.
The extent of necessary excavation shall be agreed with KOC and the unsuitable
material shall be replaced with suitably compacted approved fill material.
Excavation shall be carried out in accordance with the requirements of KOC Standard
KOC-C-005. Manual excavations shall be made, as directed by KOC, in locations where
required to protect the existing underground services.

Concrete Workg
Concrete shall be produced by weigh batching and mixed in mixer machine for pouring.
The water cement ratio of the concrete mix shall be maintained for good workability
and any adjustment needed shall be made for the aggregate moisture content at the
time of mixing.
Concrete shall be evenly spread and compacted by a vibrator to produce a dense
finish free from honeycombing, sags, bulges, thick or thin areas and any other visible
defects.
All reinforcements shall be cut, bent, placed in the formwork and inspected by KOC
before concreting in accordance with ACI 315 and ACI 318.
Curing
Curing for concrete shall be continued for at least 7 days by use of one of the following
methods :a)

Being kept damp by a continuous water spray.

b)

Being covered with continuously wet burlap or fabric pads.

c)

Being sprayed with water and immediately covered with a layer of waterproof
paper meant for curing of concrete.

The concrete surfaces below the grade level shall be painted with three coats of
modified bituminous paint, the total DFT being 1000 microns, then covered with 1000g
polyethylene membranes.
Tolerances

The top of the concrete ring wall shall be level within 3 mm (1I8 in) between any two
points of 9 m ( 30 ft) of the circumference and within
6 mm (114 in) in the total
circumference measured from the average elevation.

Backfilling & Compactio~


After the concrete ring wall being properly cured, inspected and approved by KOC, the
backfilling shall commence around ring wall for the inside and outside areas of tank
foundation.
t
Earth pad below the tank bottoms and outer areas of the ring wall shall be backfilled by
spreading evenly successive layers of gatch not exceeding 200 mm loose depth. 'Each
layer shall be rolled by rollers suitable for the type of soil and shall be thoroughly
compacted to 95% of maximum dry density at optimum moisture content ( OMC ) as
determined by ASTM D l 557, before depositing the next layer.
Prior to deposition, the fill material shall be wetted with water from KOC approved
source within
2 % of the optimum moisture content to achieve proper
compaction as per above dause 12.3.2. However, before compacting, the natural

.. DOC.

NO. KOC-C-026

Page 26 of 38

REV. 1

moisture content of the samples shall be verified at site by the Speedy Moisture Device
or similar KOC approved instrument.
The compacted surfaces shall be field-tested to satisfy the requirements described in
dause 14.0 of this Standard and shall meet all the requirements specified in KOC
Standard KOC-C-005.

The layer of sand-gravel mix shall be evenly spread over the compacted gatch and shall
be compacted to 95 % of maximum dry density.
The final layer of sand cushion below the tank bottom shall be spread when the tank
fabrication commences and shall be adequately protected with covers so as to prevent
any blowing-off of the sand partides by high winds or rain.
Membrane liner (if provided) shall be installed over the compacted gatch with minimum
joints which shall be overlapped, bonded or welded to be leak tight. Liner seam shall be
bonded to the concrete ring wall for leak tight connection. All perforations shall be
sealed.
The installation of any embedded anodes, reference electrodes and associated cables
below the earth pad for the specified cathodic protection system shall be carried out in
accordance with KOC-L-026 and as per the KOC approved procedure. Care shall be
taken that no damages to these materials shall occur during compaction of the fill
materials.
As~halticConcrete Application
General
The contractor shall submit the method statement detailing all the necessary
equipment, tools and machines to be involved into the actual laying of lining by spraying
or spreading for review and approval by KOC before any work commences.
Proportions & Mixing of Materials
The contractor shall submit for approval a proposed Job Mix Formula in line with the
proportions of the materials specified in clause 10.0 of this Standard. The contractor
shall also establish the optimum mixing temperature and shall test samples of materials
to be used in accordance with dause 15.5.3 to ensure compliance with the
requirements of this Standard prior to any applicstion of the material.
Surface Rwarstion

a)

immediately before the application of surface protective layer over the


compacted surfaces, all loose dirt, dust or other objectionable material shall be
removed by means of power broom or Mower supplemented with hand brooms.

b) Any soft spots, me- en surfaces or irregularities in the surface shall be


rectified by the contractor as directed by KOC to its full satisfaction prior to
carrying out any hrrther work.

c) The asphaltic concrete shall be applied only on the dry s u r f a k of the'compacted


outer surface of ring wall end if excessively dry, the surface shall be lightly

DOC. NO. KOC-C-026

Page 27 of 38

REV. 1

sprinkled with water just before the application to facilitate proper penetration or
bonding of material.
Application Temperature
The mix temperature shall be within the limits set out in the approved Job Mix Formula
when emptied from the mixer to a tolerance of f 1 0 % but in no case shall exceed
154 O C ( 310 O F 1. The minimum temperature of mix on delivery to job site shall not be
less than 121 O C ( 250 O F ).
Application
a)

When the compacted surfaces of the tank shoulder have been approved by KOC
and weather conditions are suitable, 75 mm (3 in) thick protective layer of hotmixed asphaltic concrete lining shall be immediately sprayed or spread over all
the clean faces to prevent erosion of earth surfaces. The application shall meet
the requirements of ASTM D3515.

b)

Following the application of lining materials, the surface shall be allowed to dry
without being disturbed for a minimum period of 48 hours or longer as may be
necessary to attain proper bond after evaporation of the volatiles from the
asphalt cement.

Protective Thickness
The thickness of surface protective layer shall be verified at site to a tolerance limits of
5% over the minimum thickness of 75 mm.

EARTH FOUNDATION WITHOUT CONCRETE RING WALL


Construction of this type of tank foundation shall comply with all the material
requirements as specified in clauses 10.1 to 10.5 except 10.4 ( in-situ concrete ) of
this Standard.
Construction of this type of tank foundation shall follow the same procedures and
requirements as specified in clauses 12.1 to 12.4 except 12.2 ( concrete works ) of
this Standard.
The ring wall made of graded crushed stone or gravel (maximum 25mm size) with fine
aggregates in accordance with clause 10.2 of this Standard shall be mixed with gatch
as binder. Layers of 150mm depth shall be compacted with mechanical tampers to the
designed slope as indicated in the approved construction drawing.
Water shall be added to the materials within f 4 % of the optimum moisture content
to achieve proper compaction equivalent of 95% of maximum dry density.
Tolerances
The top of the stone ring wall shall be level within f 3 mm (118 in) between any two
points of 9 m ( 30 ft) of the circumference and within -f12 mm (112 in) in the total
circumference measured from the average elevation.

DOC. NO. KOC-C-026

Page 28 of 38

REV. 1

REPAIR OF DEFECTS 1 DAMAGES

Subject t o visual inspection of KOC, the contractor shall remove any soft patches,
uneven surfaces or crevices by refilling and recompacting the demarcated areas of
earthworks as directed till KOC is fully satisfied with the work.
In case the test results indicate that the field compaction does not satisfy the
compaction equivalent in clause 12.3.2 of this Standard ,the contractor shall carry out
the necessary corrective measures as directed by KOC at his own expenses and
without any cost to KOC whatsoever.
All refilling and rectification of materials involved in the rectification of defective works
shall be executed in the manner so as to maintain compatibility complying with the
requirements of clauses 10.1 & 12.3 of this Standard.
Concrete Work
The concrete work or part thereof shall be deemed to be defective I damaged, if the
surface is found to bear the following :a)

Large number of honeycombing I~pallingIbulging of concrete.

b)

Large number of microcracks on surfaces due to extreme hot weather and lack of
adequate curing.

C)

Exposure of reinforcement and lack or loss of bond with concrete.

All repair and rectification work by the methods (patch work, re-concreting, epoxy
based cementitious material or guniting 1 shall be carried out by the contractor as
agreed by KOC.
Amhattic Concrete
Following application of the new asphaltic concrete over the shoulder of the tank, the
protective layer having defects / damages shall be repaired completely by the
contractor as directed by KOC. The Work or part thereof shall be deemed to be
defective, if the surface over an area of 1000 cm20r more does not meet the tolerance
limits specified in clause 12.4.7 of this Standard and / or is found to bear the following
*-

a)

Surface discontinuities such as pinholes, thin spots, voids, cracks, foreign


inclusions or contamination in the protective surface over a large area.

b) Large number of Misters, wrinkles, floods, mgs, oversprays, lumps of material.


The protective layer within the defective / damaged areas shall be cut and removed in
rectangular sections. The earth surfaces shall be deaned from any debris, lumps etc.
and the disturbed areab) shall be prepared & compacted with the selected fill materials
/ gatch following the same procedure described in dause 12.3 of this Standard.

INSPECTION AND TESTING


General
KOC shall have the right to inspect all tools and equipment ; materials and
workmanship involved in the construction of foundations for Storage Tanks to ensure
compliance with this Standard.

The contractor shall submit for KOC approval a Quality Plan and a lnspection & Test
Plan that will provide the detailed activities of the work in a chronological way. The
Inspection and Test Plan shall have columns indicating the activity, the contractual and
specification requirements, the method of verification, the acceptance criteria, the
document ( test certificate or report ) that will be generated as well as columns for
indicating KOC markings for witness (W), hold (HI, review (R), monitor (MI etc.
The contractor shall perform at all stages of Works all the inspections and appropriate
tests that are necessary to assure that the materials and workmanship meet fully the
requirements of this Standard.
Materials and Eaui~mentlnmection
All materials shall be inspected to ensure conformance with clause 10.0 of this
Standard.
All equipment to be used in the earth filling & compaction and laying of in-situ concrete
and asphaltic concrete shall be inspected to ensure compliance with the KOC Fire and
Safety Regulations.
Visual Inspection
Compacted Earth Surfaces
After the earth surfaces being compacted and trimmed to the actual profile, a visual
inspection shall be made by the contractor jointly with KOC to ensure that no soft
patches, uneven surfaces or loose dust are left on the surfaces prior to commencing
the application of sand-gravel mix or protective surface layer. Any rectification of
defective work shall be carried out in accordance with clause 14.1 of this Standard.
Concrete Work
After removal of formwork, the concrete work shall be inspected by KOC to assure that
the surfaces are free from any visible defects described in 14.2.1 of this Standard. All
repair and rectification work shall be executed by the method statements which shall
be approved by KOC.
Asphaltic Concrete
After application of asphaltic concrete materials and proper drying, it shall be
inspected t o assure that the final surfaces shall be free from any defects described in
clause 14.3 of this Standard.

DOC. NO. KOC-C-026

Page 30 of 38

REV. 1

All the required tests shall be conducted on the materials by the contractor through an
independent and reputed test laboratory, approved by KOC.
All the laboratory tests on the soil samples for selection of gat* i'suitable~fill~materials
shall be carried out in accordance with clauses 14.2.2 through 14.2.4 of KOC Standard
KOC-C-005.
All the laboratory tests on the materials specified in this Standard shall be conducted in
accordance with the relevant BS & ASTM standards to satisfy the requirements of this
Standard.
Field Tests
Earth Works

Field in-place density tests shall be performed in accordance with ASTM Dl 556 at not
less than one test for every 500 m3 of compacted fill to satisfy the compaction
equivalent in clause 12.3 of this Standard.
Smctural Concrete
a)

Prior to commencing the concrete work for ring wall construction the contractor
shall , prepare three ( 3 ) Nos. test cubes of 150 mm sizes in the standard moulds,
conforming to the grade specified. The test cubes shall be made, cured,
preserved, and tested in compliance with BS 1881 or ASTM C39 after 7 days
to indicate a compressive strength of not less than 70 % of the compressive
strength at 28 days.

b) Six (6) Nos. of representative test cubes of above sizes shall be made for every
20 m3 of concrete during the course of concrete pouring, cured, stored; and
tested, three ( 3 1 after 7 & 28 days respectively to confirm the compressive
strength specified in clause 10.4.7 of this Standard or as indicated in the approved
construction drawing.
Asphattic Concrete

a)

Sufficient number of samples shall be collected during the course of application


from the appropriate sampling points as follows:t

b)

i.

From the tanker, in case of bulk delivery by road, immediately before


discharge;

ii.

From the storage tank immediately before mixing;

iii.

From the tank or the spray bar of a bituminous distributor immediately


before spraying.

Each sample shall be immediately subdivided into three ( 3 ) test samples, stored
into dean and dry metal containers, labelled with time & date of sampling and
sampling locations.

C)

Testing of samples shall be carried out within 3 days after sampling and shall be
conducted in accordance with the test methods of ASTM D2172.

QUALITY .ASSURANCE

The contractor / manufacturer shall operate a quality system preferably based on IS0
9000 series of Standards to satisfy the requirements of this Standard. Contractor /
manufacturer shall demonstrate compliance by providing a copy of the accredited or
the contractor 1 manufacturer quality manual. Verification of a contractor quality
system is normally part of the pre-qualification procedure, and is therefore not detailed
in the core text of this Standard.
DOCUMENTATION

General
All correspondence, instructions, drawings, data sheets, design calculations or any
other information shall be in the English language. In the case of dual languages, one
language shall be English.
All dimensions, units of measurement, physical constants etc. shall be in SI units,
unless otherwise specified.
All documents (texts, specifications, data sheets, methods, drawings etc.) shall be
provided with electronic files in the approved softwares ( MsWord, Excel, Auto Cad etc.
1. Design calculations shall be submitted in the approved and widely used softwares,
agreed by KOC.
Work Records and Reports
The contractor shall operate a detailed recording and reporting system on all aspects of
works including inspections and testing. All relevant information shall be set out on a
Site Record for Foundation Works within 48 hours of carrying out a specific work. A
sample of this Site Record is shown in the Appendix - IV and shall be submitted in
duplicate.
All test results of samples ( filling material, aggregates, cement, asphalt cement etc. )
hall be submitted to KOC for review and approval within 24 hours of completion of
tests.
All field test results of samples (compacted fill, concrete cubes, asphalt concrete
etc.) shall be reported to KOC for review and acceptance within 24 hours of completion
of tests.

DOC. NO. KOC-CQ26

Page 32 of 38

REV. 1

APPENDIX- I :JYP, EARTH FOUNDATION OF TANK WITH CONCRETE RING WALL

TANK
76m.m TEICK

GATCB MIHPACI%D
g5X MAX. DRY DW

LAYER COMPACTED

To

DRY DENSllY

?OR lgAY DETECTION. PBOVDE


75mm DIAMETER PVC PIPES

OR BQUAL AT NOT YORE TEAN


SY B r m m CKNTRES AROUND
PIIRIPHWY. M
C MESH
SCBEENOVER msmE OPEN BND.

Mhnm
BUNDING --/
CONCRETE

6
A
m

COMPACTED TO

OSX MAX.

a. FANE PAD 10UNDATION SBAU COYPLY 'IFFH

06% OF MAXIMUM

RBQvnzeYwnOF THlS KOC STANDARD & -ANT


PlwBm BPICIFICILTION.

DRY DlWSITY

APPENDIX II : TYP. EARTH FOUNDATION OF TANK WITH CONCRETE RING WALL


1 WlTH EMBEDDED CATHODIC PROTECTION SYSTEM 2

75mm THICKASPHALTIC
CONCRETE

CATCH COMPACTED
05% MAX. DRY DEN

FOR LEAK DETECTION, PROVIDE--/


75mm D W T E R PVC PIPES
OR EQUAL AT NOT YORE THAN
6M B E T 5 N CENTRES AROUND

PERIPHERY. PLASTIC YESH


SCBEEN OVER INSIDE OPEN END

SOmm /
BLXNDING

CONCRETE

(lmm TOTAL THICKNESS),


COVERED m lOOOg
NOTES:
MK. DRY DENSITY TO
1. ALL DIKENQONS ARE IN YY.
FULL DEPTH OF BPJC W.
2. REINFORCED CONCRETE SHALL COMPLY WITH
BBQuDUWNTS OF PROIgCT SPECIFICATION.
a. TANK PAD FOUNDATION SHALL COMPLY WITH REQTJIREYENTS
OF THIS Itoc STANDARD & PROJECT ~ECIFICATION.
4. DEPITI: TO BE DECIDED BY TBE DESIGNER AS PER SR'B CONDITIONS
BUT NOT LESS THAN 900m.m FOR D M 5 m AND 6OOmm FOR D<95m
FROM PINISBED GRADE OR NATURAL GROUND LEVEL (NGL) WEICHEVEB I6 U l E R .
6. BgpgIl FIELEVANT DRAWINGS FOR CATHODIC PROTECTION OF TANK BOlTOYS.

7. IsJER (IF PROVIDED) TO Bg 3ONDED TO RINGWAIL ?'OR LEAK TIGHT CONNETION.

DOC. NO. KOC-C-026


APPENDIX

Page 34 of 38

REV. 1

- Ill : N P . EARTH FOUNDATION OF TANK WITHOUT CONCRETE WALL RING

El

ITANK
SHELL

7Smm THICK ASPHALTIC

~EiDmmiT,

1v-

+'

2Smm A S P U T
IYPREGNATED BOARD
OR 25mm WON-SHRINK GROUT

I--""*
loZ

3. DEPTH OF MUNDATION TO BE DBCIDQ) BY TEE Dmcm As PER


SITE CONDXTIONS BUT NOT USS TUN OOOmm Ir6LOM FDUSHED
OBaDB OR NATURAL GROUND lgVEL (NGL) VEICHgVlgR IS L
O
m

14.0

SlTE RECORD FOR FOUNDATION WORK

.................................
........................................
...................
..................................
.....................................................................
..............................
.............................................................
................................
................................
...........................
......................................
...........................

Prepared by
Checked by
Date
Project No.
Contract No.
Contractor Name
Location
Type of Work : 00 New O Repair
KOC Drawing No.
Earthwork D Concrete D Asphaltic Concrete
Type of Workmanship : 0 Site Preparation
Date of Commencement
Time
AM IPM
Date of Completion
Time
AM I PM

A.

Site Preparation Details

A. 1 Commencement Requirements
Work 1 Excavation Permit obtained
Give reasons ( if No 1
Approvals obtained
Give reasons ( if Not 1

D Yes

0 No

....................................................................................
Not Started
Started D Completed
Not Complted
.....................................................................................

A.2 Drawings Site Information

D Checked

0 Not Checked

A.3 Existing Services encountered


Give details ( if yes 1

......................................................................................

A.4 Demolition required


Give details ( if yes

...................................................................................

A.5 Site Clearance

D Not Started 0 Started 0 Completed 0 Not Completed

0 Yes

0 No

0 Yes

0 No

B. Weather Conditions

Maxm. Ambient Temperature


Minm. Ambient Temperature

..............OC
...............OC

........................

Relative Humidity
%
Other Conditions : Cl Rainy 0 Windy

C. Earthwork Details
C.l Foundation Areas Generally in
Borrow Pit required

fill
No

Cut
Yes

0 60th

C.2 Fill Materials


Excavated Materials if available
( by visual inspection 1
Soil Samples tested from
Suitable Materials
( by Lab. test results 1
Materials selected from
Soil type approved as Fill

0 Suitable

0 Unsuitable

U Borrow Pit
0 Approved

0 Mixed

0 Excavated Materials
D Not Approved

O Borrow Pit D Excavation 0 Both


.............................................................................

SITE RECORD FOR FOUNDATION WORK ( contd. )

C.3 Compaction

D.

l'ype of Equipment used

0 Vibrating Rate 0 Mechmicd Rammer 0 Any Othe; (Specify)

Compaction by Fidd Trials

D Approved

Compaction achieved

0 Yes

Give reasons ( if Not )

.................................................................................

D Not Approved

0 No

Concrete Work Details


Temperature of Concrete .................... OC
........................ Aggregates ..................... Admixture .............

.................................

Grade of Concrete
Mixing by weight : Cement

Type of Equipment used : 0 Batching Piant O Truck-mounted Concrete Mixture 0 Any other

................ Size ............................... Pressure ....................


...................................................................................
Length Covered : ..................................m Time of Application : .............................. Hr.
Curing Method .............................
Curing Period ...........................
Give reasons ( if extra period required 1 .........................................................................
Details of Equipment : Capacity
Any other

E.

protective Linina A ~ ~ l i c a t i o n
Asphaltic Concrete

................................................ Mixing Time ..................................


...................... OC Viscosity ..................................
......................... kg per 8q.m
Details if any ( Specify ) ...............................................................................................
Type of Equipment used ..............................................................................................
0.tdls of Equipment : Capacity .................... 6ite ....................... Qnuure ................
Mixing Method
Application Temperature
Application Rate

Area Covered :

..................................Sq.m

Time of Application :

..........................Hr.

---

DOC. NO. KOC-C-026

REV. 1

SITE RECORD FOR FOUNDATION WORK ( contd. )

F. lns~ection81 Testing
0 Weekly
Any Observation .........................
.............................. Concreted Surface .....................
..............................

0 Daily
Inspection Frequency :
Visual Inspection : Prepared Surface

F.l Fill Materials for Foundations

OYes
Field In-Place Density Tests done :
Field results :
0 Acceptable
Corrective measures taken ( if not acceptable 1

ONo
0 Not Acceptable

...................................................................

F.2 Concrete
Test Cube Sizes

.........................

Concrete Temperature

Compressive Strength :
At age of 7 days

............... N I sq.mm

Test results :

0 Acceptable

Corrective measures taken ( if not acceptable )

At age of 28 days

................. OC

.............. N I sq.mm

0 Not Acceptable

...............................................................

F.3 Protective Lining


Asphaltic Concrete

..................................
..................................
............OC ..........OC
.................... ...............
Lining Thickness
.................. mm

Test Samples
Mix Proportion
Application Temp.
Viscosity

Recorded By :

A ~ ~ r o v eBy
d :

..............................................
Signature .........................................
Name

REMARKS :

...................................................
Signature .............................................

Name

Page 38 of 38

DOC. NO. KOC-C-026

REV. 1

ACKNOWLEDGEMENT
This Standard has been approved by the Standards Technical Committee (STC) consisting of the
following :Mr. Ali H. Baba
Mr. Mohd. Emam
Mr. S. Kumar
Dr. Mohammad llyas
Mr. Khalid S. AI-AIi
Mr. Henry S. Hill
Mr. Jassem Al- Quraini
Mr. S. Manickavachagam

(
(
(
(
(
(
(
(

Standards Div. )
Insp. & Corr. Div.
Standards Div.
Standards Div. )
Maint. Proj. Div. )
Maint. Plng. Div. )
PMD - North )
Engg. Design Div. )

Chairman
Deputy Chairman
Secretary 1 Member
Member
Member
Member
Member
Member

The draft of this Standard has been circulated to the KOC User Departments for their review and
comments were received from the following :ENGINEERING GROUP

MAINTENANCE GROUP

Gen. Supdt. Engg. Services


Head of Team Engg. Projects ( N )
Gen. Supdt. Proj. Mgmt ( S&E

Gen. Supdt. Maint. Services


Gen. Supdt. Maint. ( N&W )
Gen. Supdt. Maint. ( S&E )

LOSS PREVENTION GROUP

INDUSTRIAL SERVICES GROUP

Gen. Supdt. Consv. & Insp.


Gen. supdt. Fire & Safety

Gen. Supdt. Ahmadi Services

PRODUCTION & EXPORT OPERATIONS GROUP


Gen.
Gen.
Gen.
Gen.

Supdt. Marine & Export Opns


Supdt. Prod. Services
Supdt. Prod. Opns ( N&W )
Supdt. Prod. Opns ( S )

This KOC Standard for Storage Tank Foundation has been prepared by the Task Force ( TF-CIV.1
01 ) comprising of the following members :Mr. S. Kumar
Mr. Javaid Masood
Mr. Khalid Al- Sayed

(Standards Div.)
(Engg. Design Div.)
(Maint. Proj. Div.)

Team Leader IAuthor


Member / Author (Part)
Member

Tel. No. 61407


Tel. No. 61322
Tel. No. 61613