Release Purpose: IFR - Issued for Review

DOCUMENT COVERSHEET

Document Information
Project No: PM210011 Project Name: NEOM Green Hydrogen Elements
Project Doc No: PM210011-CCC000-WM4-00021 Rev: 00

Client Doc No: Rev:

Contractor Doc MS-1235-231-002 Issue 10/10/2022

Rev: 00
No Date:

Document Title Method Statement for DUCT BANK Installation

VDR Code(s)

Tag No(s):(1):

Note 1 – For multiple Tag No: refer to page 2

Review Status
Sign. Steve Fortune
Status Code 4
Date: 19-Apr-2023
Code:
Status Code Legend
Code 1 Reviewed by Air Products – REJECTED Resubmit for Review
Code 2 Reviewed by Air Products – COMMENTS AS NOTED Resubmit for Review
Code 4 Reviewed by Air Products – NO COMMENTS, No Further Submittal Required Unless Drawing/Document is
Revised
Code 5 ACCEPTED FOR INFORMATION ONLY
Vendor / Sub-Contractor is not relieved of responsibility for accuracy of dimensions, performance, design, design of details or any code
requirements. Further, review by Air Products does not relieve Vendor of responsibility or liability, or from furnishing material in
conformance with the contract, purchase order, or other agreement. Air Products’ review shall not be construed as an Approval by Air
Products of such documents or an opinion by Air Products that such documents are true and accurate

Purchase Order Information

Air Products Specifier:
PO Number:
PO Date:
Contractor Name: Consolidated Contractors Company W.L.L and Consolidated
Contractors Middle East Limited
Contractor Org Code: CCC
Contractor SAP ID:

Page 1 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

CONSOLIDATED CONTRACTORS COMPANY W.L.L.

CONSOLIDATED CONTRACTORS MIDDLE EAST LIMITED

AP MIDDLE EAST INDUSTRIAL GASES LLC

Project Document Number: PM210011-CCC000-WM4-00021 CCC Document No.: MS-1235-231-002

Revision: 00

PROJECT TITLE

NEOM GREEN HYDROGEN PROJECT

Project No.: PM210011

DOCUMENT TITLE

METHOD STATEMENT

For

DUCT BANK Installation

Mohammad Abdul Roger El Hachem

00 9-Oct-2022 Issued for Review Wissam Lateef Project Director
Sayyour

Rev. Rev. Date Description Prepare Checked By Approved By

d By

Page 2 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

Record OF Revisions

Rev. No. Page/Section Description

00

Page 3 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

TABLE OF CONTENTS

1.0 SCOPE: …………………………………………………………………………………….5

2.0 PURPOSE: …………………………………………………………………………...……5

3.0 DEFINITIONS: ……………………………………………………………….………........5

4.0 REFERENCES: ……….…….……………………………………………………...……..5

5.0 PERMIT TO WORK ……………………….…………………………………………..…..6

6.0 SAFETY…………… ……………………….…………………………………………..….. 6

7.0. RESPONSIBILITIES……… ……………………….…..……………………………...…..6

8.0 EQUIPMENT / TOOLS……… …………………………………………..……………… ... 8

9.0 PROCEDURE………………………………………………..……………………………. ...8

10.0 QA/QC DOCUMENTATION…………………………..…………………………….…... 17

11.0 ATTACHMENTS………………………………………..………………………………... 17

Page 4 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

1.0 SCOPE:

• The scope of this method statement is to cover the procedure for Installation of Duct Banks. In
accordance with contract requirements, approved project specification (CQPB03.02), project
safety procedure and approved “issued for construction” drawings at NEOM Green Hydrogen
Elements Project.

2.0 PURPOSE:

• To establish the procedure to ensure that duct bank installations are accomplished in
compliance with project specifications, applicable codes, and contract requirements.

• This Method Statement will, if deemed necessary, be revised as and when required, to
accommodate circumstantial requirements that cannot be foreseen at this stage.

3.0 DEFINITIONS:

• Project : NEOM Green Hydrogen Elements Project

• Company : AP Middle East Industrial Gases LLC (AP)

• Contractor : Consolidated Contractors Company WLL

Consolidated Contractors Middle East Limited (CCC)

• ITP/QCP : Inspection Test Plan/Quality Control plan

• RFI/AFC : Request for Inspection/ Approved for Construction

• PTW / JSA : Permit to work/ Job safety Analysis

• ACI : American Concrete Institute

• ASTM : American Society for Testing and Materials

4.0 REFERENCES:

All design, engineering, materials and construction shall conform to the latest requirements of local
national standards, local regulations and the following reference documents. Latest edition at the time
of contract award shall be applicable. If these documents contain conflicting requirements, the most
stringent requirement as per the Contract shall be applicable. However, any discrepancies shall be
brought to the attention of Company for applicable standards.

• PM210011-000-ZP6-0006 : GHE Construction EH&S Plan_Rev 06

• PM210011-000-ZP6-0005 : GHE Journey Management & Transportation Safety Procedure

• 4 ACE-600700 : Construction Safety –Air Products Program

• SPEC-ENG-CV011 : Specification for concrete works
• CQPB03.02 : Duct bank installation

• CQP A03 : Basis of Operations

• CQP A09 : Quality Control Interface with contractor

• CQP A18 : Quality Control Personnel Qualification and Training

• CQP B06.01 : Concrete Mixing & Delivery

• CQP B06.02 : Concrete Placement

• CQP B10.01 : Raceway & Cable Installation

Page 5 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

• 4 ECE-M18 : Earthworks

• SPEC-ENG-CV011 : Specification for concrete works

• : General notes for Civil/structural works

• : Safe Work Instructions Trenches and Excavations

• : Environmental Protection

• : HSE Emergency Procedure

5.0 PERMIT TO WORK:

• As installation of Duct Banks are hazardous activities, they shall be carried out under Company
PTW system.

• Permit shall be raised by Contractor personnel approved for raising the PTW, and as per permit
to works regulations shall be strictly adhered to.

• Approved Drawing/ method statement shall be attached to PTW.

• Full time qualified and experienced CCC Safety Personnel with full understanding of the job in
hand will be deployed on job site during the work activities.

• All the safety precautions mentioned in the permit shall be strictly adhered till the activity
completion & permit closer.

• The permit shall be kept in a secured plastic folder at the work execution place for any eventual
inspection of the permit by AP Safety Operations Authority.

• All the permits shall be correctly filed by Contractor and recorded by PTW office.

6.0 SAFETY:

• All equipment shall be certified and in good working condition, and approved by AP and certified
as the contract requirements.

• All personnel involved in this task shall wear relevant PPE including safety helmets, safety
boots, gloves, safety glasses.

• The site shall be kept in a clean and tidy condition.

• JSA shall be prepared for the activity and shall be approved prior to the beginning of the activity.

• All safety requirements as listed in PTW shall be followed & AP safety standards shall be
applied.

• The area shall be barricaded and safety sign boards shall be bold and visible to personnel on
site.

7.0 RESPONSIBILITIES:

• Project Director /Project Manager: have the responsibility for overall project activities
including safety measures.

• Project Engineer /Construction Manager (Civil): is responsible for issuance of

cable/termination tickets (or liaison with the project engineering organization when engineering
issues the cable/termination tickets), and for maintaining site files for retention of required
documentation.
• Site Engineer shall be responsible for the following:

✓ Shall direct the installation of duct banks and associated cable pulls in compliance with
engineering specifications and drawings and applicable procedures

Page 6 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

✓ Shall verify the completion and conformance of duct bank installation activities and document
acceptance of the work via signature on the corresponding CQP Forms.

✓ Shall direct the installation of the duct bank in compliance with engineering specifications and
drawings and applicable procedures.

✓ Shall verify completion and compliance of duct bank installation activities to engineering
requirements and document acceptance of the work via signature on Form B03.02A Duct bank
Installation Checklist.

✓ Shall direct the installation and termination of electrical cables in compliance with engineering
specifications, applicable procedures and CQP B18.01.

• Site Superintendent shall be responsible for the following:

✓ Confirm the availability of work permits, materials, tools and qualified personnel who will carry
out the work.

✓ Ensure the full implementation of this Method Statement.

✓ Check the work areas for any unsafe conditions.

✓ Verify proper housekeeping shall be done in work areas.

• QA/QC Manager shall assure the implementation of this program consistent with the
engineering design and the contract

• QA/QC Engineer shall be responsible for the following:

✓ A quality control program shall be instituted that will verify or ensure that the work performed
under the contract meets the requirements of this standard and the design drawings as per
Project requirements

✓ COMPANY shall have access to all facilities and records of the Contractor for the purpose of
conducting performance inspection/audits.

✓ Conduct inspection in accordance with these procedures and COMPANY Typical Inspection
Plan.

✓ Monitor and visual inspection for every stage of the work during and after the construction
phase until the completion of the activity.

✓ Independent testing agency/ Third Party laboratory approved by COMPANY Inspection

Department can perform testing on specific requirements of the work.

✓ All relevant material approval intended for this scope of work shall be submitted separately.

✓ Records and test results shall then be gathered and kept for future use and reference

• Safety Supervisor shall be responsible for the following:

✓ All personnel shall undergo safety training before start of the work. Record of personnel
undergone safety training with details of training undergone shall be kept with HSE Department.

✓ Check daily toolboxes talks are to be conducted every morning before commence of the work
by the concerned supervisor and Job specific JSA is to be communicated to the workforce and
the details shall be documented.

✓ All personnel entering into the plant shall wear minimum approved PPE such as helmet, safety
glass, gloves, and safety shoes irrespective of the location and nature of the work.

✓ Persons working with power tools or pneumatic equipment should wear hand gloves and eye
protection. Only trained and certified personnel are allowed to operate and work with such tools.

✓ Dust masks shall be worn whenever the environment is dusty.

Page 7 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

8.0 EQUIPMENT / TOOLS:

Depending on the size of the area, site conditions, and accessibility, some /all of the following
equipment can be used.

• Concrete Mixing and transport equipment

• Ready Mix Concrete Batching Plant
• Transport mixers
• Concrete pump
• Crane 22 ton
• Hoses /Concrete shoots
• Concrete Buckets
• Air Compressor
• Slings and shackles
• Survey Equipment
• Level
• Total station (Surveying instrument for checking the levels & distances)
• Masonry Accessories (Steel and wooden Floats, Steel Brush)
• Wheel Barrows
• Concrete Vibrators

9.0 PROCEDURE:

9.1 Prerequisites
• Prior to the start of duct bank installation activities, requirements for coordination of inspections
and verifications, and associated documentation, shall be established.

• A site procedure should be established for the routing, filing, and retention of completed
Inspection Reports, as-built drawings, and other documentation as required by project
procedures, specifications, and the CQP for the project.

• Duct bank installation activities shall be controlled using a site established tracking system, as
appropriate. The Construction Supervisor/Engineer will be responsible for generating and
maintaining the forms and inter-discipline interface necessary to coordinate the combined
electrical and civil activities appropriate to duct bank installations.

9.2 General Guidelines

• The Construction Supervisor/Engineer shall direct the installation of duct banks and associated
cable pulls in compliance with engineering specifications and drawings and

• applicable procedures.

• The progress of duct bank installation activities shall be maintained by marking-up installation
drawings or a log in a manner that indicates the following status. Status may be included in
Systems Turnover and Reporting (Reference CQP A16).

✓ Duct bank work in progress.

✓ Duct bank nearly complete, inspected, and ready for cable pull.

✓ Duct bank (including cable pull) complete, inspected, and accepted.

• The Construction Supervisor/Engineer shall verify the completion and conformance of duct
bank installation activities and document acceptance of the work via signature on the
corresponding CQP Forms.

Page 8 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

I. Duct bank Installation

• The Construction Supervisor/Engineer shall direct the installation of the duct bank in
compliance with engineering specifications and drawings and applicable procedures.

• Form B03.02A, Duct bank Installation Checklist shall be prepared for each duct bank
installation to identify pertinent data concerning the installation.

• Duct bank installations shall be accomplished in accordance with the engineering

requirements.

• The Construction Supervisor / Engineer shall verify completion and compliance of duct bank
installation activities to engineering requirements and document acceptance of the work via
signature on Form B03.02A Duct Bank Installation Checklist.

II. Cable Installation

• The Construction Supervisor/Engineer shall direct the installation and termination of electrical
cables in compliance with engineering specifications, applicable procedures and CQP B18.01.

III. Inspection and verification shall assure the following

• Verify inter-discipline coordination (Civil & Electrical).

• Verify correct conduit and associated materials (correct size and type).

• Verify trench depth and routing per drawings and specifications (trench elevation, location,
dimensions and forming).

• Check for conflicts with other underground construction.

• Trench free of debris.

• Check conduit sizes, types, location and properly sloped.

• Verify rigid steel elbows used for all stub-ups, including PVC runs when required.

• Verify conduit fittings and seals are installed per the engineering design.

• Verify that the conduit position will allow minimum concrete coverage on all sides of the
conduits.

• Verify conduit spacing, supports and tie downs correct.

• Verify stub-up dimensions and location.

• Verify field bend radius correct per the engineering design and bends free of deformities.

• Verify caps on conduit ends prior to release for concrete pour.

• Verify conduit connections tightly made.

• Confirm reinforcing bars installed when specified.

• Confirm all field changes recorded on as-built.

• Trench and forms free of debris and standing water.

• Concrete pour report completed to release duct bank for pour (CQP Form B06.02B).

• Concrete coverage adequate.

• Concrete colour correct (red where required).

• Concrete encasement of stub-ups correct.

• Conduits are internally cleaned by mandrel pull.

• Verify conduit ends are clean and free of concrete.

• Check that pulling wires are in place.

Page 9 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

• Verify stub-ups have not moved during pour.

• Verify cable pull rigging is adequate to handle cable.

• Verify cable reel assignments.

• Verify cable voltage rating, minimum pulling temperature.

• Verify pulling compound is compatible with cable to be pulled.

• Verify direction of pull and method of pulling.

• Assure inspection of cables for jacket damage before pull.

• Verify cable installation in accordance with CQP B10.01

• Verify the trench is backfilled with the correct material free of stones and debris, to the correct
depth.

• Verify trench backfilled to correct elevation and required compaction tests performed.

• Assure any required duct bank markers are in place.

• Assure preparation of any required duct bank “as -built” drawings.

9.3 Pre-Requirements:
• Sub-grade Preparation and Backfill

➢ Prior for the construction of Duct Banks the base shall meet the requirements as per Form
B03.02A

• Formwork

➢ The design and construction of the formwork shall be in accordance with ACI

➢ Plywood forms, Lumber forms, Metal forms, Form oil, Form sealer, Form accessories,
Screed chairs and Chamfer stripes shall conform to the requirements.

• Concrete (SPEC-ENG-CV011)

➢ Before starting the work for concreting activities, the correspondent information from the
Project's engineering of the element or concrete structure to be poured should be available.
Concrete shall be taken from the COMPANY approved batching plant only. All concrete mix
design shall be approved by the COMPANY Approval Procedure for Ready-Mixed Concrete
Mix Design). Contractor intends to utilize sufficient concrete batch plant companies located
sufficiently close to the site in order to ensure the continuity of supply and cater the big
quantity of concrete pouring periods and ready mix concrete from approved supplier shall
be used.

9.4 Materials

• Material of welded wire mesh work.

➢ Fusion bonded epoxy coated (FBE) or galvanized welded wire mesh shall conform to project
standards with minimum yield strength of 422MPa.

➢ Installation of the welded wire mesh at site will be as per IFC Drawings

9.5 Procedure of Formwork

• Surface Conditions.

➢ Examine the substratum and conditions under which concrete formworks are to be
performed. Correct unsatisfactory conditions which would interfere with proper and timely
completion of the Works. Do not proceed until unsatisfactory conditions have been
corrected.
Page 10 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

9.6 Form Construction

• General

➢ Fabricate forms complying with ACI 347, to the exact sizes, shapes, lines, and dimensions
shown, and as required to obtain accurate alignment, location, grades, level, and plumb
work in finish structures.

• Fabrication

➢ Fabricate forms for easy removal without hammering or prying against Concrete surfaces.
Provide crush plates or wrecking plates where stripping may damage cast concrete
surfaces. Provide top forms for inclined surfaces where the slope is too steep to place
concrete with bottom forms only. Kerf wood inserts for forming key- ways, recesses, and the
like, to prevent swelling and assure ease of removal.

• False-work

➢ Erect false-work and support, brace and maintain it to safely support vertical, lateral, and
asymmetrical loads applied until such loads can be supported by in-place construction.
Construct false- work so that adjustments can be made for take-up and settlement.

➢ Provide wedges, jacks, or camber strips to facilitate vertical adjustments. Carefully inspect
false-work and form work during and after concrete placement operations to determine
abnormal deflection or signs of failure; make necessary adjustments to produce work of
required dimensions.

• Forms for exposed concrete

➢ Provide sharp, clean corners at intersecting planes, without visible edges or offsets. Back
joints with extra studs or girds to maintain true, square intersections.

➢ Use extra studs, wale, and bracing to prevent objectionable bowing between forms and
studs and to avoid bowed appearance in concrete. Do not use narrow strips of form material
that will produce bow.

➢ Assemble forms so that they may be readily removed without damage to exposed concrete
surfaces.

• Cleaning and Tightening

➢ Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood,
sawdust, dirt, and other debris just before concrete is placed. Retighten forms immediately
after concrete placement as required to eliminate mortar leaks.

• Form Coatings

➢ When forms are coated to prevent bond with concrete before welded wire mesh placing, the
coating shall not have excess form coating material to accumulate in the forms or to come
into contact with surfaces which will be bonded to fresh concrete. Apply in compliance with
manufacturer's instructions. Coat steel forms with a non-staining, rust-preventative form oil
or otherwise protect against rusting Rust-stained steel formwork is not acceptable.
Formwork release agent shall be approved by COMPANY prior to use.

➢ Shores and Supports

✓ Comply with ACI 347 for shoring and re-shoring in multistorey construction.

➢ Removal of Forms

✓ Forms should be removed after achieving the required minimum strength in

accordance with ACI 347.

➢ Re-use of Forms

✓ Clean and repair surfaces of forms to be re-used in the work. Split, frayed, delaminated
or otherwise damaged form facing material will not be acceptable. Apply new form

Page 11 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

coating compound material to concrete contact surfaces as specified for new formwork.
When forms are re- used for successive concrete placement, thoroughly clean
surfaces, remove fins and laitance, and tighten forms to close all joints. Align and
secure joints to avoid offsets.

9.7 Procedure for Welded Wire Mesh work

• General

➢ Manufacture, fabrication, handling, placement and storage of welded wire mesh shall be in
accordance with Chapter 7 of ACI 318. Handling and fabrication of the epoxy coated or
galvanized welded wire mesh shall be in accordance with ASTM A775 Appendix, and
Concrete Reinforcing Steel Institute (CRSI).

• Cutting and bending

➢ All bending details must be correct. Unless closer limits are stated in the contract
documents, straight bars have a length tolerance of 1 in Bent bars are usually measured
from outside to outside of bar, but some organizations use center-to center dimensions.

➢ Regardless of bending tolerances, all parts of bars must have the specified cover. If welded
wire mesh will be job fabricated, use a bending pin diameter not less than the recommended
sizes in ACI 318. Different pin diameters are required for different grades of steel (Grades
40, 60) If several bars will be bent alike, check the first one bent, preferably by placing it in
the forms, before the others are bent.

➢ Do not bend or straighten steel in a manner that would weaken the material.

• Storage and handling

➢ Storage and Handling of FBE or galvanized welded wire mesh shall conform to project
standards

➢ Before welded wire mesh is placed, the surface must be free from objectionable coatings or
heavy corrosion.

➢ Remove other objectionable coatings such as oil, grease, dried mud, and weak dried mortar
or concrete. Brush weak mortar from the bars and remove it from the forms. If it is difficult
to remove, it is probably harmless and need not be removed.

• Welded Wire Mesh Installation

➢ Welded wire mesh is embedded a minimum distance from the surface of the concrete
(clearance), to prevent buckling under certain conditions of a compressive load, rusting
when exposed to weather, or loss of strength when exposed to fire.

➢ Check clearance at stirrups and column ties that project beyond other welded wire mesh
and to clearance under sagging horizontal bars midway between supports.

➢ If there is more than one mat of welded wire mesh, align bars vertically above each other in
both horizontal directions to minimize interference with placing and consolidating concrete.

➢ Provide preplanned openings in the upper mat for drop chutes to help prevent scattering
and segregation of the concrete.

➢ Especially where welded wire mesh is congested, the nominal maximum size of aggregate
in the concrete mix must not exceed three-quarters of the minimum clear spacing between
bars so as to permit satisfactory placement of concrete around the bars.

➢ Placed concrete shall be consolidated by mechanical vibrating equipment supplemented by

hand spading, rodding or tamping. Equipment and procedure for consolidation of concrete
shall be in accordance with ACI 309R. Use vibrator heads that fit between bars in congested
areas. If small vibrators are used, reduce the spacing of vibrator insertion locations and

Page 12 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

increase vibrating time. Use immersion-type vibrators with nonmetallic heads when
consolidating concrete around epoxy-coated or galvanized welded wire mesh.

• Support of Welded wire mesh

➢ All welded wire mesh must be firmly held in place before and during the casting of concrete.

➢ The use of precast concrete or mortar blocks as bar supports and spacers discussed in ACI
301-05 shall be prohibited. However, the use of PVC (notched at the bottom) Schedule 80
pipe as spacer is allowed

➢ Use a sufficient quantity and strength of bar supports and spacers to support both welded
wire mesh and construction loads.

➢ Do not use rocks, wood blocks, or other unapproved objects to support the steel.

➢ Use chairs on the ground that are sufficiently large enough to prevent settling by indenting
the soil.

➢ Support horizontal bars every 5 or 6 ft. in general for specific recommendations.

➢ Tie wires and bars supports or chair bars for FBE coated or galvanized welded wire mesh
shall be epoxy coated.

• Field checking procedure

➢ During concrete pouring a stand by surveyor and carpenter must be on site to fix any
displacement or movement of forms.

• Procedure of PVC Pipe Installation

➢ All PVC Pipes shall be inspected by QC Material Inspector/coordinator and approved by the
COMPANY before it's withdrawn from the stores.

➢ All PVC Pipes shall be Type EB-35 or Type DB-120 as per project standards for concrete
encased conduit and for Direct buried shall use Type DB-120.

➢ All PVC Pipes shall be place using PVC spacer in accordance of the project specifications
and with IFC drawings.

➢ The QC Inspector shall check the formwork, steel welded wire mesh, PVC Pipes prior to
concrete placing.

➢ When Duct Bank was separated with pits and duct bank level is under the pit will be lower,
bell ends shall be installed at the end of each PVC sleeves.

9.8 QC Inspection of other Trades (E&I and Telecom)

➢ Prior for concreting schedule, the Contractor shall coordinate the pouring to other QC
Inspectors from Electrical, Instrument and Telecom to check their concern area for
inspection including the testing required.

➢ All the inspection from other disciplines should get approval prior to proceed the concreting
works of particular duct banks.

➢ Ensure that Clearance document showing acceptance of the duct bank requirements from
Electrical or Telecom is attached to the pre-concreting RFI.

9.9 Procedure of Concrete

• Concrete Mixing

➢ Concrete to be mixed at approved batch plants. Transit mixing is not allowed. Batch plants
must comply with the requirements of ACI 304, with sufficient capacity to produce concrete
of the quantities required to meet the construction schedule.

Page 13 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

➢ In duct banks with steel conduit, unreinforced non-structural concrete [with minimum 28 day
design compressive strength of 14 Mpa (2000 psi)] shall be used.

➢ In duct banks with PVC conduit, under areas with no traffic, or occasional traffic (including
roads with occasional traffic), unreinforced non-structural concrete [with minimum 28 day
design compressive strength of 14 Mpa (2000 psi)] shall be used.

➢ In duct banks with PVC conduit, under areas with frequent traffic, such as roads and parking
lots inside plants or communities, reinforced concrete [with minimum 28 days design
compressive strength of 28 Mpa (4000 psi)] shall be used.

• Ready Mix Concrete

➢ Comply with the requirements of SPEC-ENG-CV011 provided the quantity and rate of
delivery permitting unrestricted progress of the work in accordance with the placement
schedule. During hot weather or under condition contributing to rapid sitting of concrete, a
shorter mixing time other than that specified in SPEC-ENG-CV011 may be required.
Proposed changes in mixing procedures must be accepted by COMPANY before
implementation.

• Preparation of Concrete Pouring

➢ Before starting the pouring of the concrete will have to request the inspection by QC
Inspector and that the necessary measures were taken to realize the laboratory tests. In
case the activities are not performed by any reason, will reprogram the date and hour of the
notification in the same format being in common agreement with the parts involved. This
format will be kept open by the quality control inspector being properly supported.

➢ After the inspection notification is distributed proceed to fill format which should be properly
approved to request the concrete supply.

➢ The subgrade preparation shall be as per SPEC-ENG-CV011

• Pouring and Compaction of the Concrete

➢ To proceed with the pouring of the concrete, additional manpower and equipment must be
utilized as required, depending on the quantity of pouring. Shovels, wheelbarrows, canals,
rubber sleeves, piping, transporting bands or pumping equipment are used for conveying
and consolidation of concrete during pouring. The most commonly used equipment for
consolidation are internal vibrators (immersion), for this case the number of vibrators will be
sufficient enough depending on the quantity and type of structures to be poured. Additional
vibrator will be in place as a spare in which it will compensate any vibrators that will have a
breakdown. A minimum of two vibrators will be added as a spare. Equipment made of
aluminum alloys shall not be used for pump lines, tremies, or chutes used to discharge
concrete from a truck mixer.

➢ The elements that will end up partially submerged in the concrete should be firmly fastened
in their place according to the planes/drawings of the project.

➢ At the arrival of the concrete, the canals and equipment necessary for the managing of the
concrete should be wet (without affecting mix water content).

➢ The unit ticket for the Concrete shall be verified to obtain the information concerning the
characteristics used. For its later usage.

➢ The Third Party Representative will inspect the slump and the temperature of the concrete.

➢ Concrete shall not be placed prior to a recorded pre-placement inspection and authorization
to proceed by the COMPANY

➢ Concrete shall be deposited as near as possible in its final position to avoid segregation due
to re-handling or flowing. The concrete should be poured without interruptions as near as
possible to its final place or it may be poured in big quantities in a determined place and
allow it to flow through.

Page 14 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

➢ The concrete shall be placed on a clean surface. Standing water shall be removed prior to
placement of concrete. It will have to be placed in horizontal layers of uniform thickness
(concrete layer shall not exceed 450 mm); the pouring speed should be sufficiently fast to
avoid the curing of the concrete layer before the new layer is placed over.

➢ Concrete shall not be dropped freely where reinforcing will cause segregation nor shall it be
dropped freely more than 1m.

➢ For the compaction of the concrete after obtaining a leveled surface a vibrator should be
inserted in a vertical form spacing it regularly and in a uniform manner over the entire surface
poured, the distance between the intersections should be of approximately 1 ’/ times the
action radius of the vibrator. Raking shall not be used for movement of concrete after
placement

➢ Re-tempering of concrete after placement is prohibited. Vibrators shall not be used to move
concrete inside forms.

➢ The vibrator should rapidly penetrate all the way through the bottom of concrete.

➢ When Duct Bank thickness is greater than 1200 mm (48 in) thick, the designer should
consult ACI 207.2R and other ACI mass concrete requirements for concrete mixes and
installation. For construction of mass concrete Subcontractor shall consult ACI 207.1R (e.g.
reduce heat of hydration through cementitious material content control, precooling, post
cooling, and proper construction management practices).

• Testing and Inspection

➢ Performed field and laboratory testing which shall include compressive tests of molded
concrete cylinders, test for slump, unit weight, air content (where air-entrainment is required)
and fresh concrete temperature. All testing shall be in accordance with SPEC-ENG-CV011
“Ready-Mix Portland Cement Concrete".
➢ Independent COMPANY approved 3rd party testing centre required to perform field and
laboratory testing.

• Curing of the Concrete

➢ Performed curing of concrete by moist curing for at least 7 days as specified by SPEC-ENG-
CV011

➢ Keeping the surface of the concrete continuously wet by covering with water.

➢ The saturated burlaps shall be covered with a plasticized sheet vapor barrier, minimum
0.15mm (6mils) in thickness and shall be kept in contact with the concrete surface at all
times.

➢ When the atmospheric temperature is 30 deg. Centigrade and above, or during other
climatic conditions which will cause too rapid drying of the concrete, make arrangements
before the start of concrete placing for the installation of wind breaks or shading, or wet
sprinkling, moisture retaining covering. Protect the concrete curing period. Provide hot
weather protection complying with the requirements of ACI 305. Maintain concrete
temperature as uniformly as possible, and protect from rapid atmospheric Temperature
changes in concrete.

➢ During the curing period, protect concrete from damaging mechanical disturbance including
load stresses, heavy shock, excessive vibration, and from damage caused by rain or flowing
water. Protect all finished concrete surfaces from damage by subsequent construction
operations.

➢ When Curing Compound is used it shall be in accordance with ASTM C309 or equivalent,
and as detailed in SPEC-ENG-CV011

Page 15 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

9.10 Procedure of Bituminous Coating

• General

➢ Bituminous Protection coating can only be applied to hardened concrete which has been
cured for a minimum of 7 days and has a dry surface, to avoid blistering of coating. Concrete
must pass the required moisture test. Suitably trained and supervised labor shall be used to
carry out the application of the protection system.

• Preparation

➢ After removal of shutters/formworks the surface of cast concrete shall be inspected for
defects. Surfaces to received coating shall be smooth and free from laitance, release agent
and Residual curing agent (if not compatible with bituminous system) If these items are
present they shall be removed by wire brushing. Surface defects and small holes (maximum
size 10mm) identified in initial inspection, shall be filled with mortar and re-inspected prior to
application of coating system. Prior to the application of the protection system, the concrete
surfaces shall have been Inspected and released for coating.

➢ Cracks less than 10 mm wide and holes not exceeding 10 mm in diameter shall be filled
using a qualified epoxy filler or grout before applying primer/sealer to the surface.

➢ New Concrete must have a moisture content of 4% or less before the coating applications
commence.

➢ Application of coating

➢ The first coat can be applied to the surfaces of the concrete using either brush or shot haired
roller. Care should be taken not to apply the coating to the above ground concrete since this
will have to be removed later.

➢ After the application of the first coat, the wet film thickness shall be checked using a gauge
supplied the bituminous manufacturer. The painted surface s hould be checked form “pin
holes”.
➢ The second coat will be applied as per the manufacturer recommendation. The completed
surfaces shall be re-inspected and it must be approved by COMPANY prior to Backfilling.
Dry Film Thickness (DFT) Report must be provided.

➢ The coating contractor's personnel shall be qualified in accordance to the standard

procedure with substantial track records in previous concrete coating applications

➢ Detailed coating application procedure including scope of work, quality and inspection plan
shall be submitted & get approved before commencing application.

➢ Detailed coating application procedure including scope of work, quality and inspection plan
shall be submitted & get approved before commencing application

9.11 Instructions

• Instruction of formwork

➢ Form shall be installed according to relevant IFC detail drawings. Location and elevation
shall be surveyed prior to commencement of formwork for matching with IFC drawings.

➢ Forms shall be substantial and sufficiently tight to maintain adequate strength to contain the
fluid concrete and to prevent leakage from the concrete pouring.

➢ Forms shall be built to resist the pressures to which they will be subjected and to limit
deflections to a practicable minimum within the specified tolerance.

Page 16 of 17
Project Document Number: PM210011-CCC000-WM4-00021 Release Purpose: Issued for Review Rev: 00

➢ Forms shall be properly braced or tied together to maintain position and shape.

➢ Forms shall be anchored properly to prevent movement during concrete pouring.

• Instruction of Steel welded wire mesh work

➢ The work checklist is summary of work instruction. The intent of the work checklist is to
provide a listing of all activities associated with concrete welded wire mesh that may require
inspection or verification.

➢ All welded wire mesh shall be procured as per the details in approved Material Requisition.

➢ Ensure that material is properly lifted and slung so as to avoid any twisting, bending or over
stressing of the material.

➢ Ensure that there are adequate storage facilities and protection from weather or other
damage for the material.

➢ Ensure that the material is properly supported off the ground, stored on sleepers 450mm
above the ground, so as not to camber the material or cause damage to the coatings.

➢ Check the welded wire mesh has been correctly cut bent and placed according to the
relevant drawing(s).

➢ Check the welded wire mesh for any significant coating damage and identify any repair
areas.

➢ Ensure that any epoxy coating damage has been repaired in accordance with the agreed
and approved procedure.

➢ Inspect the welded wire mesh for any visible reductions in sections, kinks, transverse cracks
or other significant damage. Any item found to be non- conforming shall be rejected and
quarantined.

➢ Check that the placement of welded wire mesh is in accordance with the approved shop
drawing(s) and bending schedule.

➢ Verify the correct sizes of placed welded wire mesh's are in accordance with the approved
drawings.

➢ Check that the spacing, ties, spacers, chairs, hangers, laps, and orientation of the welded
wire mesh is correct.

➢ Check that the epoxy coating or galvanized welded wire mesh has not sustained any further
damage.

➢ Check that the welded wire mesh is sufficiently secured to avoid any displacement.

➢ Check that there are no unapproved splice joints.

➢ Ensure that when the welded wire mesh's placed, that there is sufficient concrete cover.

➢ Check that all tie-wires are turned inside of the section.

➢ Check that the welded wire mesh's and surrounding are clean and free from any debris likely
to be detrimental to the integrity of the finished product.

10.0 QA/QC DOCUMENTATION:

• All inspection/testing as identified in related Inspection Test Plan shall be conducted. Relevant
check sheets shall be completed and shall be obtained signature from Company in line with
approved ITP. Details of sampling and testing at site acceptance criteria of DUCT BANK
Installation. Also, related activities shall be in accordance with approved ITP.

11.0 ATTACHMENTS:
Job safety Analysis

Page 17 of 17