IMS LEVEL 3 DOCUMENTS

STATEMENT OF METHOD

THERMAL AND WATER CURING OF DRAIN CHANNELS

AND COVER SLABS
IMS CODE NO.: KPC-014-PRD-007
REVISION : 00

140

PREPARED BY ISSUED TO PROJECT / CLIENT

Bechtel Overseas, Inc. Ma’aden Aluminum Smelter
NAME Mark Santana
Plant Project
TITLE KPC-QA

DATE 21/10/2010

SIGNATURE

DATE OF ISSUANCE : 21 OCT 2010

PREVIOUS REVISION NO. & DATE OF ISSUANCE : N/A
 THERMAL AND WATER CURING OF DRAIN
CHANNELS AND COVER SLABS
METHOD STATEMENT

TABLE OF CONTENTS

1.0 Title

2.0 Methodology
2.1 General Description
2.2 Equipment
2.3 Materials
2.4 Preparation
2.5 Work & Methodology

3.0 Quality Assurance

3.1 Contractual Requirements
3.2 Responsibility
3.3 Inspection & Testing

4.0 Safety & Health

4.1 Protective Safety Equipment
4.2 Environmental Safety & Health Contractor Requirements
4.3 MSDS
4.4 Risk Assessment

5.0 References

6.0 Figures

7.0 Attachments
7.1 Heater Specifications
7.2 Thermocouple Specifications
7.3 Forms

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1.0 TITLE

Steam and Water Curing of PC Units

2.0 SCOPE OF WORK

2.1 GENERAL DESCRIPTION

This document outlines the procedure for Thermal and Water Curing of PC Units
for Ma’aden Aluminum Smelter Plant Project in Jubail, Kingdom of Saudi Arabia. Bechtel
Overseas, Inc. is the Main Contractor and Al Kifah Precast Company is the sub-contractor
sub
forr manufacture and delivery of required Precast Concrete Units and responsible for
compliance with this procedure.

Curing is defined as the maintenance of satisfactory moisture content and

temperature in concrete during its early stages so that desired properties
pro may develop
(ACI 116R-90).

KPC will apply two-stage

two curing system as follows:

a. Thermal Curing as described in Bechtel Specification No. 25457-0000-3PS-

25457
0001. Thermal Curing corresponds to Accelerated Curing of Concrete
DB00-0001
Using Radiant Heat and Moisture (PCI-MNL-116,, Sec. 4.21.3). This is done
while the PC Units are in the mould inside the Factory to achieve the required
stripping, release and lifting strength of concrete at an earlier time.
b. Water
ater Curing which is curing by moisture retention without the use
supplemental heat. This is done after the units are transferred
transfe to designated
area in the Stockyard.
S

Applicable Bechtel Specifications and Industry Codes

odes pertaining to the subject are
quoted and followed.

2.2 EQUIPMENT

List of Equipment:
Equipment

A. For Thermal Curing

1. Heaters / Blower (see Sec. 7.0, Attachments)

KPC to use Heaters with the following specifications:
- Brand : Dimplex Model No. CFH90
- Max. Temp. = 55°C
- Heat Output = 9.0 kW
- Noise = 60 dB
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- Airflow = 900 m3/h

- Throw = 10m
- Temperature Control with Built-In In Thermostat, Automatic Adjustment
based on settings
2. Electronic Surface Thermocouples, with Pins (see Sec. 7.0,
Attachments)
3. Radiator, Fan (for Air Circulation)
4. Hollowcore Bed Water
Water Heating Pipes (Optional)
5. Thermometer
6. Rubberized Tarpaulin
7. Expanded Polystyrene

B. For Water Curing

1. Hessian Cloth / Burlaps

2. Approved Water Source

2.3 MATERIALS

No materials required.

2.4 PREPARATION

Prior application of heat for thermal curing, ensure that the concrete had
achieved the required initial setting time as per Bechtel Specification No. 25457-0000-
25457
0001 “Furnishing & Delivering Ready Mix Concrete” Sec. 3.3 – Initial Setting
3PS-DB01-0001
Time,, which should not be in any case less than 1 hour and as determined by the time
Concrete Compressive Strength achieved 3.4 MPa (500 psi).

2.5 WORK METHODOLOGY

A. Accelerated Curing of Concrete using Radiant Heat and Moisture (Thermal

Curing):

1. After ensuring that the concrete has achieved the initial set, the heaters
are placed and arranged in such a way that all areas will be heated
uniformly (see Section 6.0, Fig. 1 & 2).
2. Rubberized Tarpaulin and Expanded Polystyrene to be installed in such a
way that the units are thoroughly covered and minimal heat escapes from
the contraption. Moisture is maintained using a cover of moist
burlap/hessian cloth. Double the thickness at corners and edges for a
distance of 300mm.
3. Cube Samples for Compressive Tests
Tests should be cured the same way as the
parent concrete.
4. Monitor the interior and surface temperature of the unit using embedded

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thermocouples tied to a continuous logging and recording system. Install at

least 2 thermocouples (one as spare) in the location where the maximum
internal temperature is expected (generally the mass center). Initially,
install thermocouples on each exposed face of the element. Install these
instruments at mid-point
mid point of the cover zone. As experience is gained as to
the behavior of the
the mix, the total number of surface thermocouples may be
reduced to two.
5. Measure ambient air temperature using thermometers.
6. Temperature Control (see Section 6.0, Fig. 3)
a. Pre-Heat
Pre Temperature should be set at Ambient Temperature +20°C for
1 hour (+0.33°C/min).
b. Acquire Temperature Readings every 30 minutes at this stage, and
c
closely monitor the differential temperature. No two portions of the
unit should have a temperature difference of more than 20°C.
c. Maintain the rate
r of adding 20°C per hour until the concrete reaches
the maximum allowable temperature at 65°C.
d. Adjust the setting of heaters as necessary. Add or remove heaters as
per actual condition. Localized “Hot Areas” should be avoided. Bed
Heating Pipes may be used to adjust the heating uniformity
uniformi as
necessary
e. Maintain the temperature at 65°C and monitor every 1 hr if first time
until the required stripping and lifting strength is achieved. Lifting
strength is equal to 60% of the design concrete strength as directed by
the Materials Engineer.
f. Allowable
All cooling rate is at -28°C per hour (-0.50°C/min).
0.50°C/min). Cooling must
continue until the concrete temperature is no more than 22°C above
the ambient temperature outside the enclosure to prevent surface
cracking.
g. Remove insulation in stages in such a way thattha the maximum allowable
temperature differential is not exceeded (20°C), and until the surface
temperature is within 10°C of Ambient Temperature.
h. Subsequent monitoring of heating of precast concrete units may be
reduced to every 3 hours (for Pre- and Heating ing Cycle)
Cycle and every 6 hours
(for Cooling Cycle)) upon a clear demonstration that no thermal cracks
and other damage were incurred during first irst 3 batches of units.
7. The moulds are stripped and moved to designated area in Stockyard for
water curing.

B. Water Curing

1. Approved units are transferred to designated area in the Stockyard for

Water Curing.
2. Thoroughly cover individual units with pre-saturated
pre saturated hessian cloth. Use
U
minimum of 2 layer hessian cloth.
3. Double layer polythene sheet is not required if the units are thermal-cured.
the

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4. Water used for curing must be the same water used for the production of
concrete.
5. Water is manually sprinkled until the hessian cloth and the precast unit is
thoroughly wet. Water curing will be considered satisfactory if at any time
the concrete
concr surface is damp to touch.
6. No curing compound should be used.
7. Water curing should be for seven (7) consecutive days.
8. Inspect curing minimum twice at daytime and once at night for signs of
drying. Replenish water as required.
9. If drying is discovered, re-wet
re wet and increase the inspection frequency.

3.0 QUALITY ASSURANCE

3.1 CONTRACTUAL REQUIREMENTS

1. Acceptance criterion will be based on Bechtel Specification No. 25457-

25457
0000
0000-3PS-DB00-0001 “Concrete Work” and other relevant Bechtel
Specifications and Inspection and Test Plan – Post-Pour
Post Inspection (KPC-
014--ITP-011.1.
2. Bechtel Resident Engineer or his representative must be given a copy of
report on daily basis. The Bechtel Resident Engineer may also be present
while the inspection is being conducted.

3.2 RESPONSIBILITY

The following personnel are responsible for the conduct of this Operational
Procedure:

1. Thermal Curing: Ramesh Lama – Production Engineer

2. Water Curing: Ferdinand Gurion / Eduardo Sison – Production Engineer,
Stockyard
3. Inspection: Alfred Comendador – QC Engineer, Freddie Toledana – QC
Supervisor Alfred Carpio – QC Supervisor
Supervisor,
4. Document Control and Review: Alfred Comendador – QC Engineer, Mark
Santana – IMS-MR
5. Inspection and Document Review: Vinod Kannath - Bechtel Resident QC
Engineer

3.3 INSPECTION & TESTING

1. Frequency
Frequency of measurement within the unit must cover all units at
intervals specified in the Work Methodology.

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2. Equipment
All measuring equipment must be thoroughly inspected prior to
use:

a. Thermocouple – must be calibrated by duly-approved

approved calibration
agency.
b. Thermometers - must be calibrated by duly-approved
approved calibration
agency.

Heat/Blowers need not to be calibrated, but performance measured

using above mentioned instruments.

3. Records
The following Forms must be used on each specified Quality Control
Points:

Quality Form Form Code Preparation ITP Reference

Control Point No. Code
Post-Pour Post-Pour
KPC-014-F-
Thermal Curing Inspection Each Unit Inspection (KPC-
QAC-034
Report 014-ITP-012.1)
Post-Pour Post-Pour
KPC-014-F-
Water Curing Inspection Each Unit Inspection (KPC-
QAC-034
Report 014-ITP-012.1)
Calibration of Calibration Calibration of
KPC-014-F- Updated as
Measuring of Equipment (KPC-
QAC-026 required
Devices Equipment 014-ITP-014.1)
Reporting of Quality
NC and
Non- KPC-014-F- Each Non-
Non Management
CAPA Log
Conformance / QAC-032 Conformity System (KPC-014-
Sheet
CAPA ITP-000.1)

Records shall be kept in KPC QC Department and copies distributed

to Bechtel Resident Engineer duly noted by KPC QC Engineer or his
representative.

KPC QA/QC Department copy is kept for minimum of two (2) years.

4.0 HEALTH & SAFETY

4.1 PROTECTIVE & SAFETY EQUIPMENT

The following are the list of Personal Protective Equipment to be used by

personnel conducting this activity:

1. Hard Hat
H

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2. Safety Shoes
3. Cotton Gloves

4.2 ENVIRONMENTAL SAFETY & HEALTH SUB-CONTRACTOR

CONTRACTOR REQUIREMENTS

Personal Protective Equipment

4.3 MSDS (MANUFACTURER SAFETY DATA SHEET)

SHEET

Not Applicable

4.4 RISK ASSESSMENT

Not Applicable

5.0 REFERENCES

Concrete Work”
Bechtel Specification No. 25457-0000-3PS-DB00-0001 “Concrete Work
Revision 000,
000 07 May 2010

Cement and Concrete Terminology”

ACI 116 R-90 “Cement Terminology
American Concrete Institute (ACI)
PO Box 9094, Farmington Hills, MI 48333-9094

Manual for Quality Control for Plants and Production of Structural Precast Concrete
“Manual
Products, 3rd Edition”
Edition PCI Manual MNL-116,
Precast/Prestressed Concrete Institute (PCI)
175 West Jackson Blvd., Chicago, Illinois 60604

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6.0 FIGURES

HEATER
Fig. 1:: Heater and Mould Assembly
For Drain Channels (mayay be modified
as per actual conditions).. Note the
movement of air through direct
heater blower throw (10m) and
subsequent heat movement through
convection.

STEEL SHEET (TO

AVOID DIRECT
HEAT THROW
COLLISION BUT
TRANSFER
RADIANT HEAT)

DIRECT HEAT
THROW

HEATED AIR
MOVEMENT
THROUGH
CONVECTION
(SAME AS ON
UPPER PORTION)

HEATER

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DIRECT HEAT
HEATER THROW
BED HEATING
PIPES

Fig. 2:: Heater and Mould Assembly for Cover Slabs. Bed Heating Pipes are used to ensure uniform
heating and temperature controlled at the Boiler Room.

TIME Variable: TIME Variable: TIME Variable:

Time Ambient - Peak 60% Conc. Peak - Ambient
Temp. Strength Temp.
100
Concrete Strength
90
Curing Temperature
80

70 Peak Temp. @ 65°C

Conc. Lifting Strength
60

50

40

30 Initial Ambient Temp.

20

10
°C Initial Setting Time
0
Pre-Heat @ Sustained Cooling
Water Curing Stage (7 Days min.)
+27°C/hr Heating @ -28°C/hr

Thermal Curing Stage Water Curing Stage

Fig. 3: Thermal Curing Temperature and Concrete Compressive Strength Relationship (Note: for
illustrative
llustrative purposes only; actual conditions may vary but must not exceed the limits set in this
document)

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7.0 ATTACHMENTS
7.1 HEAT BLOWERS

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7.2 SURFACE THERMOCOUPLE

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8.0 FORMS
8.1 CONCRETE POUR CARD
8.2 POST-POUR
POUR INSPECTION REPORT
8.3 CALIBRATION OF EQUIPMENT
8.4 NC AND CAPA LOG SHEET

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