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GP 04-01-01
Concrete Design and Construction
November 2005
Concrete Design and Construction GP 04-01-01 Scope 1) [I] This Global Practice (GP) covers the design and construction of concrete structures. 2) [I] An asterisk (*) indicates that additional information from Owner is required or approval by Owner is required.
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GP 04-01-01
Concrete Design and Construction
November 2005
Table of Contents Table of Tables .............................................................................................................. 3 1.
Required References ............................................................................................ 4 1.1. 1.2.
2.
ACI–American Concrete Institute ................................................................. 4 ASTM–American Society for Testing and Materials ..................................... 4
Additional References .......................................................................................... 4 2.1. 2.2. 2.3.
Global Practices–ExxonMobil Engineering Practices ................................... 5 ACI–American Concrete Institute ................................................................. 5 ASTM–American Society for Testing and Materials ..................................... 5
3.
Materials................................................................................................................. 5
4.
Construction .......................................................................................................... 8 4.1. 4.2. 4.3.
Placement .................................................................................................... 8 ts ............................................................................................................ 8 Finishing ....................................................................................................... 8
5.
Concrete Design.................................................................................................... 9
6.
Inspection and Testing ....................................................................................... 10
7.
Additional Requirements for Marine Structures ............................................... 10
8.
Additional Requirements for Liquid Retaining Structures .............................. 11
Record of Change ....................................................................................................... 12 Attachment: Purpose Codes Definitions.................................................................. 13
RFCH Page 2 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Table of Tables Table 1: Application and Compressive Strength of Concrete .................................. 7 Table 2: Finishes for Horizontal Surfaces .................................................................. 8 Table 3: Minimum Time for Form Removal ................................................................ 9
RFCH Page 3 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
1. Required References 1) This Section lists Practices and Standards that are referenced and assumed to be a part of this document. Unless otherwise specified herein, use the latest edition. 2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the following provisions are met: a) The resultant design meets the safety and serviceability criteria attained through this GP. b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's Engineer.
1.1.
ACI–American Concrete Institute
ACI 117/117R
Standard Specification for Tolerances for Concrete Construction and Materials
ACI 301
Specifications for Structural Concrete
ACI 308R
Guide to Curing Concrete
ACI 318/318R
Building Code Requirements for Structural Concrete and Commentary
1.2.
ASTM–American Society for Testing and Materials
ASTM A 615/A 615M
Standard Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement
ASTM C 31/C 31M
Standard Practice for Making and Curing Concrete Test Specimens in the Field
ASTM C 94/C 94M
Standard Specification for Ready-Mixed Concrete
ASTM C 150
Standard Specification for Portland Cement
ASTM C 192/C 192M
Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory
2. Additional References 1) The following Practices and Standards shall be used with this GP as applicable. 2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the following provisions are met: a) The resultant design meets the safety and serviceability criteria attained through this GP. b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's Engineer. RFCH Page 4 of 13
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GP 04-01-01
2.1.
Concrete Design and Construction
Global Practices–ExxonMobil Engineering Practices
GP 07-01-01
Fired Heaters
GP 16-03-01
Wiring Methods and Material Selection
2.2.
November 2005
ACI–American Concrete Institute
ACI 207.1R
Mass Concrete
ACI 207.2R
Effect of Restraint, Volume Change, and Reinforcement on Cracking of Mass Concrete
ACI 305R
Hot Weather Concreting
ACI 306R
Cold Weather Concreting
ACI 350/350R
Code Requirements for Environmental Engineering Concrete Structures and Commentary
ACI 357R
Guide for the Design and Construction of Fixed Offshore Concrete Structures
2.3.
ASTM–American Society for Testing and Materials
ASTM A 767/A 767M
Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement
ASTM A 775/A 775M
Standard Specification for Epoxy-Coated Steel Reinforcing Bars
3. Materials 1) [I] Concrete shall be per ACI 318/318R. 2) [R] All reinforcing bars shall be ASTM A 615/A 615M Grade 60 unless otherwise specified. 3) * [I] Contractor shall submit a statement detailing the concrete mix design for approval by the Owner's Engineer. This statement shall include properties of the materials, proportions of cement, water and aggregates by weight and type, and quantity of ixtures (if any) proposed for each class of concrete required. 4) [R] Concrete mix design shall consider environmental exposure and potential chemical attack and shall specify the use of beneficial ixtures such as air entrainment, fly ash, and other pozzolanic materials. 5) [R] Maximum water cementitious ratio shall be minimized to maximize durability but shall in no case be more than 0.50. The maximum water cementitious ratio shall be 0.40 where the concrete will be exposed to either a chloride or marine environment and 0.45 when exposed to freezing/thawing conditions, deicing chemicals, or a sulfate environment. RFCH Page 5 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
6) Concrete mix design should consider the potential for alkali silica reaction in the concrete and whether field tests are required. 7) [R] Design strength of concrete mixes shall be in accordance with ACI 318/318R for service exposure and not less than those given in Table 1 and the following: a) In countries where testing is done on cubes, cylinders shall also be made and tested in order to establish a correlation between the required strengths for the cylinder and the cube specimens. b) Lacking adequate laboratory facilities for testing such cylinders, the 28-day compressive strengths of 4 in., 6 in., and 8 in. cubes (100, 150, and 200 mm) must be at least 130 percent, 125 percent, and 120 percent respectively, of specified cylinder strengths. 8) * [R] Cement shall be per ASTM C 150 and selection of cement type shall be governed by the following: a) For concrete exposed to soils or other materials having low pH values (less than 5.0 if continuous replenishment of acidity), special cement type or other measures may be required as directed by the Owner's Engineer. b) Selection of cement type for concrete for structures exposed to seawater environment shall be per ACI 318/318R for "moderate exposure," except that the maximum water-cement ratio shall be 0.40. 9) * [R] ixtures shall be approved by the Owner's Engineer. Calcium chloride ixtures shall not be used.
RFCH Page 6 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Table 1: Application and Compressive Strength of Concrete
Group
Application
Minimum Compressive Strength (2) psi (MPa)
A
Concrete for structures located in a marine environment
5000 (34.5)
B
Prestressed or precast concrete structures Precast piling Liquid retaining structures Concrete for fireproofing
4000 (27.6)
C
Precast pipe Precast concrete sills, copings, and all ornamental concrete Reinforced concrete chimneys Foundations for tanks in sulfuric acid service
3500 (24.1)
D
Girders, beams, walls, slabs, piers, and columns Superstructure for docks and bridges Pipe s Concrete on or below grade, such as footings, cast-in-place piles, pile caps, tie beams, grade beams, anchor blocks, pump blocks, catch basins, manholes, sidewalks and paving(1) Concrete for structures not listed
3000 (20.7)
E
Concrete for underground electrical (protective cover, etc.)
2000 (13.8)
F
Low strength concrete for filling purposes where mass, rather than strength, is the principal requirement
1500 (10.3)
Notes: (1)
For concrete exposed to moderate sulfate attack (per ACI 318/318R) and where cement with less than 8 percent C3A is not available, cement with up to 12 percent C3A may be used if approved by Owner's Engineer, and provided that concrete strength is increased to at least 3500 psi.
(2)
The values above represent the 28-day compressive strength of normal Portland cement concrete (or 7-day compressive strength of high-early strength concrete) as determined by tests on 6 in. diameter by 12 in. high (150 mm x 300 mm) cylinders per ASTM C 31/C 31M or ASTM C 192/C 192M.
10) [R] All reinforcement shall be bent-cold. 11) [R], [M] All concrete used for underground electrical work shall be per GP 16-03-01. 12) [R] All concrete used for underground air ducts for fired heaters shall be per GP 07-01-01.
RFCH Page 7 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
4. Construction [I], [R] Concrete construction shall be per ACI 301 and ACI 318/318R and the following:
4.1.
Placement
1) * [R] Concrete shall not be placed prior to approval from the Owner's Engineer. 2) [R] Concrete placement shall be in accordance with the recommendations per ACI 306R when the ambient temperature drops below 40°F (4°C). 3) [R] Concrete placement shall be in accordance with the recommendations per ACI 305R when the ambient temperature exceeds 90°F (32°C). 4) [R] Field alterations of the concrete mix proportions are prohibited unless approved by Manufacturer and Owner's Engineer. 5) [R] Concrete poured against earth shall have the soil prewetted or sealed with a vapor barrier to prevent excessive loss of moisture from the fresh concrete.
4.2.
ts
* [I] Construction, contraction, and expansion ts shall be located as specified. Any additional ts shall be approved by the Owner's Engineer. Expansion ts shall be constructed with approved preformed filler material and adequately sealed with an approved sealant.
4.3.
Finishing
1) [R], [M] Surface finishes for horizontal surfaces shall be as specified in Table 2 unless otherwise specified.
Table 2: Finishes for Horizontal Surfaces Surface
Finish
Area Paving
Broom or Belt
Compressor House Floors
Broom or Belt
Cooling Tower Basin, Flume
Floated
Curbs
Broom or Belt
Foundations and Pedestals to be Grouted
Scratched
Platforms, Stair Pads, Concrete Stairs
Broom or Belt
Pumps Slabs
Broom or Belt
Seal Slabs
None
Surfaces to be Covered with Resilient Flooring (Asphalt Tile, Etc.)
Troweled
Stucco or Mortar Base
Scratched
RFCH Page 8 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Surface
Finish
Suction Pits
Floated
Terrazzo Base
Scratched
2) [R] Unless otherwise specified, the vertical surfaces of walls, foundations, and other formed structures shall be finished as follows: a) Surfaces shall remain as they are when the forms are removed, except holes left by withdrawal of form ties shall be filled solid with grout and finished to match the surrounding surface. b) Rubbing of surfaces is not required. 3) [R] All exposed corners and edges of concrete shall have 3/ 4 in. chamfer unless otherwise specified on the design drawings. 4) [R] Concrete curing shall be per ACI 308R. Minimum time for form removal after concrete placement shall be per Table 3 provided that the forms are not necessary for the structural of the concrete.
Table 3: Minimum Time for Form Removal Minimum Time (hours) Standard (ASTM C150, Type I) Cement Concrete
Standard (ASTM C150, Type III) Cement Concrete
Tank Rings, Pump Foundations and Similar Low Structures
24
18
Walls, Columns, and Similar Tall Structures
48
24
Bottom
168
72
Side Forms
24
18
Type of Construction
Horizontal Beams or similar components which require bottom :
5. Concrete Design 1) [I] Concrete design shall be per ACI 318/318R. 2) * [O], [R] For inground structures the safety factor against flotation shall be not less than 1.2 for both normal operation and erection. Buoyant forces shall be calculated with the ground water level
RFCH Page 9 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
assumed to be at the finished grade elevation. Pressure relief systems, deliberate flooding, or other extraordinary methods to prevent flotation shall only be used if approved by the Owner's Engineer. 3) * [I] The extent of paving and toes walls within process unit areas to control spillage, and for drainage of storm, process and firewater shall be specified. 4) * [R] Pump slab areas handling corrosive chemicals shall have the paved areas around the pumps and other equipment and toe walls coated as specified. 5) * [I] Concrete duct designs for air temperatures greater than 200°F (93°C) shall be approved by the Owner's Engineer. 6) [I] Embedded items, such as inserts, hangers, pipe s and sleeves, conduits and drains, shall be adequately secured before concrete is placed. 7) [R] When the least dimension of a concrete element is greater than 4 ft (1.2 m), concrete construction and temperature control shall be per ACI 207.1R and ACI 207.2R to prevent thermally induced cracking during hydration.
6. Inspection and Testing 1) * [R] Concrete requiring a compressive strength of 3,000 psi (20.7 MPa) or more shall be tested in accordance with ACI 318/318R, except as follows: a) One test shall be taken for each day's pour and at least one test be taken for each 50 cubic yards (38 m3) placed. In addition, at least one test shall be made for each foundation exceeding 20 cubic yards (15 m3). b) A test shall consist of four cylinders. One such cylinder shall be tested in the laboratory after seven days and two after 28 days with results submitted to the Owner's Engineer as soon as possible. Testing of the remaining cylinder shall be performed as directed by the Owner's Engineer. 2) * [O], [R] Concrete showing structural defects shall be repaired or replaced by a method which has been approved by the Owner's Engineer. Concrete showing surface defects shall be patched. 3) [R] Air content, slump, and temperature tests shall be taken from the concrete samples for each strength test and whenever the consistency of the concrete appears to vary.
7. Additional Requirements for Marine Structures 1) [I] The three zones of exposure to be considered on a marine structure are: a) The submerged zone, which can be assumed to be continuously covered by water. b) The splash zone, the area subject to continuous wetting and drying. c) The atmospheric zone, the portion of the structure above the splash zone. 2) [R] Minimum cover over reinforcing steel shall be 2.5 in. (65 mm). 3) * [R] Where specified, reinforcing steel shall be galvanized per ASTM A 767/A 767M or epoxy coated per ASTM A 775/A 775M to increase their corrosion resistance. RFCH Page 10 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
4) Selection of cement type for concrete for structures exposed to seawater environment shall be designed and constructed per ACI 357R.
8. Additional Requirements for Liquid Retaining Structures 1) [I] Liquid retaining structures shall include inground concrete pits sensitive to groundwater intrusion and aboveground or inground concrete structures required to contain liquids. 2) [R] Liquid retaining structures shall be designed and constructed for liquid tightness according to the provisions of ACI 350/350R, except structural design considerations shall be as clarified in Section 8, Item 3, below. 3) * [R] To minimize cracking and leakage, design of concrete walls, slabs and other elements which serve to retain liquids shall be in accordance with the following criteria: a) Minimum thickness and changes in thickness shall be as follows: i) Walls up to 10 ft (3 m) high shall have a minimum thickness of (4+0.8 H) in. [(100+67 H) mm] but not less than 8 in. (200 mm) where H equals the wall height in feet (meters). The minimum thickness for walls above 10 ft (3 m) in height shall be 12 in. (305 mm). ii) Slabs shall have a minimum thickness of 10 in. (250 mm). iii) Changes in wall or slab thickness shall be accomplished using tapered sections having a minimum length of three times the change in thickness. b) Reinforcing bar diameters shall not exceed 6 percent of the thickness of the wall or slab. c) Expansion ts shall be spaced not more than 50 ft (15 m) apart for exposed and not more than 80 ft (24 m) apart for completely underground. d) Construction ts not shown on the drawings shall be approved by the Owner's Engineer. 4) * [R] Construction of liquid retaining structures shall conform to ACI 301 and the following: a) The surface of concrete at all ts shall be thoroughly cleaned and all laitance removed before placing ading concrete. b) Special liners and coatings shall be used to protect concrete surfaces from degradation by harmful liquids. Materials used for liners and coatings shall be approved by the Owner's Engineer. 5) * [R] Structures required to contain liquid shall a water-tightness test approved by the Owner's Engineer.
RFCH Page 11 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Record of Change Version 1.0.0 Location
Action
Date: 02/02
Description Initial Publish.
Version 1.1.0 Section 5
Addition
Date: 03/02
Added Purpose Code [I] to Item 6
Version 1.1.0
Date: 07/03
Global Practice version number and format updated to comply with new process; however, original publish date remains, and no content was modified.
Version 2.0.0
Date: 11/05
Section 2.2
Addition
Reference to ACI 207.1R and ACI 207.2R for mass concrete design considerations.
Section 2.2
Addition
Reference to ACI 357R for concrete located in marine environments.
Section 3, Items (4) – (6)
Addition
Requirements to ensure durability of concrete.
Section 3, Item (5b)
Modification
Selection of concrete located in marine environment shall be in accordance with ACI 357R in lieu of ACI 318. Item moved to Section 7, Item (4). Also eliminated maximum water cement ratio of 0.40.
Section 3, Item (10)
Deletion
Duplicate requirements already specified in ACI 318.
Section 3, Item (11)
Deletion
Duplicate requirements already specified in ACI 318.
Table 1 – Group A
Modification
Clarified that marine environment includes both brackish and freshwater environments.
Table 1 – Group B
Modification
Eliminated reference to structures continuously exposed to freshwater.
Section 5, Item (7)
Addition
Reference to ACI 207.1R and ACI 207.2R for design of mass concrete.
Section 7, Item (2)
Modification
Minimum cover for concrete structures in marine environment.
Version 2.0.0
Date: 12/05
Upstream initial customization to Version 2.0.0.
RFCH Page 12 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Attachment: Purpose Codes Definitions Code
Description
C
Assigned to paragraphs containing specifications whose primary purpose is reduced costs. Reduced cost in this context refers to initial investment cost and does not include Life-Cycle cost considerations. Life-Cycle cost considerations are captured under reliability, maintainability, or operability purpose codes.
E
Assigned to paragraphs containing specifications whose primary purpose is driven by environmental considerations. Environmental considerations typically include specifications intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained in such paragraphs require formal review and approval according to local environmental policy.
I
Assigned to paragraphs that provide only clarifying information such as Scope statements, definitions of , etc.
M
Assigned to paragraphs containing specifications whose primary purpose is to provide for maintainability of equipment or systems. Maintainability provisions are those that facilitate the performance of maintenance on equipment/systems either during downtimes or during onstream operations.
O
Assigned to paragraphs containing specifications whose primary purpose is to assure operability of equipment or systems. Operability is the ability of the equipment/system to perform satisfactorily even though conditions are off-design, such as during start-ups, process swings, subcomponent malfunction, etc.
R
Assigned to paragraphs containing specifications whose primary purpose is to improve or assure the reliability of equipment or systems. Reliability is a measure of the ability of equipment/systems to operate without malfunction or failure between planned maintenance interventions.
S
Assigned to paragraphs containing specifications whose primary purpose is avoidance of personnel or operational safety incidents. Any deviation from the specifications contained in such designated paragraphs requires formal review and approval according to local safety policy. Personnel Safety:
Refers to the avoidance of recordable personnel injuries—i.e., burns, cuts, abrasions, inhalation, or exposure to dangerous substances, etc., that could result in medical treatment, restricted work, lost-time incidents, or fatalities.
Operational Safety:
Refers to the prevention and control of process releases, fires, explosions, etc.
RFCH Page 13 of 13
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Concrete Design and Construction
November 2005
Concrete Design and Construction GP 04-01-01 Scope 1) [I] This Global Practice (GP) covers the design and construction of concrete structures. 2) [I] An asterisk (*) indicates that additional information from Owner is required or approval by Owner is required.
Refining/Chemicals Page 1 of 13
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Version 2.0.0
GP 04-01-01
Concrete Design and Construction
November 2005
Table of Contents Table of Tables .............................................................................................................. 3 1.
Required References ............................................................................................ 4 1.1. 1.2.
2.
ACI–American Concrete Institute ................................................................. 4 ASTM–American Society for Testing and Materials ..................................... 4
Additional References .......................................................................................... 4 2.1. 2.2. 2.3.
Global Practices–ExxonMobil Engineering Practices ................................... 5 ACI–American Concrete Institute ................................................................. 5 ASTM–American Society for Testing and Materials ..................................... 5
3.
Materials................................................................................................................. 5
4.
Construction .......................................................................................................... 8 4.1. 4.2. 4.3.
Placement .................................................................................................... 8 ts ............................................................................................................ 8 Finishing ....................................................................................................... 8
5.
Concrete Design.................................................................................................... 9
6.
Inspection and Testing ....................................................................................... 10
7.
Additional Requirements for Marine Structures ............................................... 10
8.
Additional Requirements for Liquid Retaining Structures .............................. 11
Record of Change ....................................................................................................... 12 Attachment: Purpose Codes Definitions.................................................................. 13
RFCH Page 2 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Table of Tables Table 1: Application and Compressive Strength of Concrete .................................. 7 Table 2: Finishes for Horizontal Surfaces .................................................................. 8 Table 3: Minimum Time for Form Removal ................................................................ 9
RFCH Page 3 of 13
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Version 2.0.0
GP 04-01-01
Concrete Design and Construction
November 2005
1. Required References 1) This Section lists Practices and Standards that are referenced and assumed to be a part of this document. Unless otherwise specified herein, use the latest edition. 2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the following provisions are met: a) The resultant design meets the safety and serviceability criteria attained through this GP. b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's Engineer.
1.1.
ACI–American Concrete Institute
ACI 117/117R
Standard Specification for Tolerances for Concrete Construction and Materials
ACI 301
Specifications for Structural Concrete
ACI 308R
Guide to Curing Concrete
ACI 318/318R
Building Code Requirements for Structural Concrete and Commentary
1.2.
ASTM–American Society for Testing and Materials
ASTM A 615/A 615M
Standard Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement
ASTM C 31/C 31M
Standard Practice for Making and Curing Concrete Test Specimens in the Field
ASTM C 94/C 94M
Standard Specification for Ready-Mixed Concrete
ASTM C 150
Standard Specification for Portland Cement
ASTM C 192/C 192M
Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory
2. Additional References 1) The following Practices and Standards shall be used with this GP as applicable. 2) [I] Local codes and standards may be substituted for the ones referenced herein, provided the following provisions are met: a) The resultant design meets the safety and serviceability criteria attained through this GP. b) Substitution is accepted by the authorities where the facility is to be located and by the Owner's Engineer. RFCH Page 4 of 13
For ExxonMobil Use Only ExxonMobil Development Company
Version 2.0.0
GP 04-01-01
2.1.
Concrete Design and Construction
Global Practices–ExxonMobil Engineering Practices
GP 07-01-01
Fired Heaters
GP 16-03-01
Wiring Methods and Material Selection
2.2.
November 2005
ACI–American Concrete Institute
ACI 207.1R
Mass Concrete
ACI 207.2R
Effect of Restraint, Volume Change, and Reinforcement on Cracking of Mass Concrete
ACI 305R
Hot Weather Concreting
ACI 306R
Cold Weather Concreting
ACI 350/350R
Code Requirements for Environmental Engineering Concrete Structures and Commentary
ACI 357R
Guide for the Design and Construction of Fixed Offshore Concrete Structures
2.3.
ASTM–American Society for Testing and Materials
ASTM A 767/A 767M
Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement
ASTM A 775/A 775M
Standard Specification for Epoxy-Coated Steel Reinforcing Bars
3. Materials 1) [I] Concrete shall be per ACI 318/318R. 2) [R] All reinforcing bars shall be ASTM A 615/A 615M Grade 60 unless otherwise specified. 3) * [I] Contractor shall submit a statement detailing the concrete mix design for approval by the Owner's Engineer. This statement shall include properties of the materials, proportions of cement, water and aggregates by weight and type, and quantity of ixtures (if any) proposed for each class of concrete required. 4) [R] Concrete mix design shall consider environmental exposure and potential chemical attack and shall specify the use of beneficial ixtures such as air entrainment, fly ash, and other pozzolanic materials. 5) [R] Maximum water cementitious ratio shall be minimized to maximize durability but shall in no case be more than 0.50. The maximum water cementitious ratio shall be 0.40 where the concrete will be exposed to either a chloride or marine environment and 0.45 when exposed to freezing/thawing conditions, deicing chemicals, or a sulfate environment. RFCH Page 5 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
6) Concrete mix design should consider the potential for alkali silica reaction in the concrete and whether field tests are required. 7) [R] Design strength of concrete mixes shall be in accordance with ACI 318/318R for service exposure and not less than those given in Table 1 and the following: a) In countries where testing is done on cubes, cylinders shall also be made and tested in order to establish a correlation between the required strengths for the cylinder and the cube specimens. b) Lacking adequate laboratory facilities for testing such cylinders, the 28-day compressive strengths of 4 in., 6 in., and 8 in. cubes (100, 150, and 200 mm) must be at least 130 percent, 125 percent, and 120 percent respectively, of specified cylinder strengths. 8) * [R] Cement shall be per ASTM C 150 and selection of cement type shall be governed by the following: a) For concrete exposed to soils or other materials having low pH values (less than 5.0 if continuous replenishment of acidity), special cement type or other measures may be required as directed by the Owner's Engineer. b) Selection of cement type for concrete for structures exposed to seawater environment shall be per ACI 318/318R for "moderate exposure," except that the maximum water-cement ratio shall be 0.40. 9) * [R] ixtures shall be approved by the Owner's Engineer. Calcium chloride ixtures shall not be used.
RFCH Page 6 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Table 1: Application and Compressive Strength of Concrete
Group
Application
Minimum Compressive Strength (2) psi (MPa)
A
Concrete for structures located in a marine environment
5000 (34.5)
B
Prestressed or precast concrete structures Precast piling Liquid retaining structures Concrete for fireproofing
4000 (27.6)
C
Precast pipe Precast concrete sills, copings, and all ornamental concrete Reinforced concrete chimneys Foundations for tanks in sulfuric acid service
3500 (24.1)
D
Girders, beams, walls, slabs, piers, and columns Superstructure for docks and bridges Pipe s Concrete on or below grade, such as footings, cast-in-place piles, pile caps, tie beams, grade beams, anchor blocks, pump blocks, catch basins, manholes, sidewalks and paving(1) Concrete for structures not listed
3000 (20.7)
E
Concrete for underground electrical (protective cover, etc.)
2000 (13.8)
F
Low strength concrete for filling purposes where mass, rather than strength, is the principal requirement
1500 (10.3)
Notes: (1)
For concrete exposed to moderate sulfate attack (per ACI 318/318R) and where cement with less than 8 percent C3A is not available, cement with up to 12 percent C3A may be used if approved by Owner's Engineer, and provided that concrete strength is increased to at least 3500 psi.
(2)
The values above represent the 28-day compressive strength of normal Portland cement concrete (or 7-day compressive strength of high-early strength concrete) as determined by tests on 6 in. diameter by 12 in. high (150 mm x 300 mm) cylinders per ASTM C 31/C 31M or ASTM C 192/C 192M.
10) [R] All reinforcement shall be bent-cold. 11) [R], [M] All concrete used for underground electrical work shall be per GP 16-03-01. 12) [R] All concrete used for underground air ducts for fired heaters shall be per GP 07-01-01.
RFCH Page 7 of 13
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Version 2.0.0
GP 04-01-01
Concrete Design and Construction
November 2005
4. Construction [I], [R] Concrete construction shall be per ACI 301 and ACI 318/318R and the following:
4.1.
Placement
1) * [R] Concrete shall not be placed prior to approval from the Owner's Engineer. 2) [R] Concrete placement shall be in accordance with the recommendations per ACI 306R when the ambient temperature drops below 40°F (4°C). 3) [R] Concrete placement shall be in accordance with the recommendations per ACI 305R when the ambient temperature exceeds 90°F (32°C). 4) [R] Field alterations of the concrete mix proportions are prohibited unless approved by Manufacturer and Owner's Engineer. 5) [R] Concrete poured against earth shall have the soil prewetted or sealed with a vapor barrier to prevent excessive loss of moisture from the fresh concrete.
4.2.
ts
* [I] Construction, contraction, and expansion ts shall be located as specified. Any additional ts shall be approved by the Owner's Engineer. Expansion ts shall be constructed with approved preformed filler material and adequately sealed with an approved sealant.
4.3.
Finishing
1) [R], [M] Surface finishes for horizontal surfaces shall be as specified in Table 2 unless otherwise specified.
Table 2: Finishes for Horizontal Surfaces Surface
Finish
Area Paving
Broom or Belt
Compressor House Floors
Broom or Belt
Cooling Tower Basin, Flume
Floated
Curbs
Broom or Belt
Foundations and Pedestals to be Grouted
Scratched
Platforms, Stair Pads, Concrete Stairs
Broom or Belt
Pumps Slabs
Broom or Belt
Seal Slabs
None
Surfaces to be Covered with Resilient Flooring (Asphalt Tile, Etc.)
Troweled
Stucco or Mortar Base
Scratched
RFCH Page 8 of 13
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Concrete Design and Construction
November 2005
Surface
Finish
Suction Pits
Floated
Terrazzo Base
Scratched
2) [R] Unless otherwise specified, the vertical surfaces of walls, foundations, and other formed structures shall be finished as follows: a) Surfaces shall remain as they are when the forms are removed, except holes left by withdrawal of form ties shall be filled solid with grout and finished to match the surrounding surface. b) Rubbing of surfaces is not required. 3) [R] All exposed corners and edges of concrete shall have 3/ 4 in. chamfer unless otherwise specified on the design drawings. 4) [R] Concrete curing shall be per ACI 308R. Minimum time for form removal after concrete placement shall be per Table 3 provided that the forms are not necessary for the structural of the concrete.
Table 3: Minimum Time for Form Removal Minimum Time (hours) Standard (ASTM C150, Type I) Cement Concrete
Standard (ASTM C150, Type III) Cement Concrete
Tank Rings, Pump Foundations and Similar Low Structures
24
18
Walls, Columns, and Similar Tall Structures
48
24
Bottom
168
72
Side Forms
24
18
Type of Construction
Horizontal Beams or similar components which require bottom :
5. Concrete Design 1) [I] Concrete design shall be per ACI 318/318R. 2) * [O], [R] For inground structures the safety factor against flotation shall be not less than 1.2 for both normal operation and erection. Buoyant forces shall be calculated with the ground water level
RFCH Page 9 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
assumed to be at the finished grade elevation. Pressure relief systems, deliberate flooding, or other extraordinary methods to prevent flotation shall only be used if approved by the Owner's Engineer. 3) * [I] The extent of paving and toes walls within process unit areas to control spillage, and for drainage of storm, process and firewater shall be specified. 4) * [R] Pump slab areas handling corrosive chemicals shall have the paved areas around the pumps and other equipment and toe walls coated as specified. 5) * [I] Concrete duct designs for air temperatures greater than 200°F (93°C) shall be approved by the Owner's Engineer. 6) [I] Embedded items, such as inserts, hangers, pipe s and sleeves, conduits and drains, shall be adequately secured before concrete is placed. 7) [R] When the least dimension of a concrete element is greater than 4 ft (1.2 m), concrete construction and temperature control shall be per ACI 207.1R and ACI 207.2R to prevent thermally induced cracking during hydration.
6. Inspection and Testing 1) * [R] Concrete requiring a compressive strength of 3,000 psi (20.7 MPa) or more shall be tested in accordance with ACI 318/318R, except as follows: a) One test shall be taken for each day's pour and at least one test be taken for each 50 cubic yards (38 m3) placed. In addition, at least one test shall be made for each foundation exceeding 20 cubic yards (15 m3). b) A test shall consist of four cylinders. One such cylinder shall be tested in the laboratory after seven days and two after 28 days with results submitted to the Owner's Engineer as soon as possible. Testing of the remaining cylinder shall be performed as directed by the Owner's Engineer. 2) * [O], [R] Concrete showing structural defects shall be repaired or replaced by a method which has been approved by the Owner's Engineer. Concrete showing surface defects shall be patched. 3) [R] Air content, slump, and temperature tests shall be taken from the concrete samples for each strength test and whenever the consistency of the concrete appears to vary.
7. Additional Requirements for Marine Structures 1) [I] The three zones of exposure to be considered on a marine structure are: a) The submerged zone, which can be assumed to be continuously covered by water. b) The splash zone, the area subject to continuous wetting and drying. c) The atmospheric zone, the portion of the structure above the splash zone. 2) [R] Minimum cover over reinforcing steel shall be 2.5 in. (65 mm). 3) * [R] Where specified, reinforcing steel shall be galvanized per ASTM A 767/A 767M or epoxy coated per ASTM A 775/A 775M to increase their corrosion resistance. RFCH Page 10 of 13
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Concrete Design and Construction
November 2005
4) Selection of cement type for concrete for structures exposed to seawater environment shall be designed and constructed per ACI 357R.
8. Additional Requirements for Liquid Retaining Structures 1) [I] Liquid retaining structures shall include inground concrete pits sensitive to groundwater intrusion and aboveground or inground concrete structures required to contain liquids. 2) [R] Liquid retaining structures shall be designed and constructed for liquid tightness according to the provisions of ACI 350/350R, except structural design considerations shall be as clarified in Section 8, Item 3, below. 3) * [R] To minimize cracking and leakage, design of concrete walls, slabs and other elements which serve to retain liquids shall be in accordance with the following criteria: a) Minimum thickness and changes in thickness shall be as follows: i) Walls up to 10 ft (3 m) high shall have a minimum thickness of (4+0.8 H) in. [(100+67 H) mm] but not less than 8 in. (200 mm) where H equals the wall height in feet (meters). The minimum thickness for walls above 10 ft (3 m) in height shall be 12 in. (305 mm). ii) Slabs shall have a minimum thickness of 10 in. (250 mm). iii) Changes in wall or slab thickness shall be accomplished using tapered sections having a minimum length of three times the change in thickness. b) Reinforcing bar diameters shall not exceed 6 percent of the thickness of the wall or slab. c) Expansion ts shall be spaced not more than 50 ft (15 m) apart for exposed and not more than 80 ft (24 m) apart for completely underground. d) Construction ts not shown on the drawings shall be approved by the Owner's Engineer. 4) * [R] Construction of liquid retaining structures shall conform to ACI 301 and the following: a) The surface of concrete at all ts shall be thoroughly cleaned and all laitance removed before placing ading concrete. b) Special liners and coatings shall be used to protect concrete surfaces from degradation by harmful liquids. Materials used for liners and coatings shall be approved by the Owner's Engineer. 5) * [R] Structures required to contain liquid shall a water-tightness test approved by the Owner's Engineer.
RFCH Page 11 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Record of Change Version 1.0.0 Location
Action
Date: 02/02
Description Initial Publish.
Version 1.1.0 Section 5
Addition
Date: 03/02
Added Purpose Code [I] to Item 6
Version 1.1.0
Date: 07/03
Global Practice version number and format updated to comply with new process; however, original publish date remains, and no content was modified.
Version 2.0.0
Date: 11/05
Section 2.2
Addition
Reference to ACI 207.1R and ACI 207.2R for mass concrete design considerations.
Section 2.2
Addition
Reference to ACI 357R for concrete located in marine environments.
Section 3, Items (4) – (6)
Addition
Requirements to ensure durability of concrete.
Section 3, Item (5b)
Modification
Selection of concrete located in marine environment shall be in accordance with ACI 357R in lieu of ACI 318. Item moved to Section 7, Item (4). Also eliminated maximum water cement ratio of 0.40.
Section 3, Item (10)
Deletion
Duplicate requirements already specified in ACI 318.
Section 3, Item (11)
Deletion
Duplicate requirements already specified in ACI 318.
Table 1 – Group A
Modification
Clarified that marine environment includes both brackish and freshwater environments.
Table 1 – Group B
Modification
Eliminated reference to structures continuously exposed to freshwater.
Section 5, Item (7)
Addition
Reference to ACI 207.1R and ACI 207.2R for design of mass concrete.
Section 7, Item (2)
Modification
Minimum cover for concrete structures in marine environment.
Version 2.0.0
Date: 12/05
Upstream initial customization to Version 2.0.0.
RFCH Page 12 of 13
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GP 04-01-01
Concrete Design and Construction
November 2005
Attachment: Purpose Codes Definitions Code
Description
C
Assigned to paragraphs containing specifications whose primary purpose is reduced costs. Reduced cost in this context refers to initial investment cost and does not include Life-Cycle cost considerations. Life-Cycle cost considerations are captured under reliability, maintainability, or operability purpose codes.
E
Assigned to paragraphs containing specifications whose primary purpose is driven by environmental considerations. Environmental considerations typically include specifications intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained in such paragraphs require formal review and approval according to local environmental policy.
I
Assigned to paragraphs that provide only clarifying information such as Scope statements, definitions of , etc.
M
Assigned to paragraphs containing specifications whose primary purpose is to provide for maintainability of equipment or systems. Maintainability provisions are those that facilitate the performance of maintenance on equipment/systems either during downtimes or during onstream operations.
O
Assigned to paragraphs containing specifications whose primary purpose is to assure operability of equipment or systems. Operability is the ability of the equipment/system to perform satisfactorily even though conditions are off-design, such as during start-ups, process swings, subcomponent malfunction, etc.
R
Assigned to paragraphs containing specifications whose primary purpose is to improve or assure the reliability of equipment or systems. Reliability is a measure of the ability of equipment/systems to operate without malfunction or failure between planned maintenance interventions.
S
Assigned to paragraphs containing specifications whose primary purpose is avoidance of personnel or operational safety incidents. Any deviation from the specifications contained in such designated paragraphs requires formal review and approval according to local safety policy. Personnel Safety:
Refers to the avoidance of recordable personnel injuries—i.e., burns, cuts, abrasions, inhalation, or exposure to dangerous substances, etc., that could result in medical treatment, restricted work, lost-time incidents, or fatalities.
Operational Safety:
Refers to the prevention and control of process releases, fires, explosions, etc.
RFCH Page 13 of 13
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