kpc-014-prd-008_thermal and moisture curing of pc units procedure

8/8/2019 KPC-014-PRD-008_Thermal and Moisture Curing of PC Units Procedure

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I

THERMAL AND

DATE OF ISSUANCE

PREVIOUS REVISION NO.&DATE OF ISS

PREPARED BY

NAME Mark Santana

TITLE KPC-QA

DATE 21/10/2010

SIGNATURE

SLEVEL 3DOCUMENTSSTATEMENT OF METHOD

ATER CURING OF DRAIAND COVER SLABS

MSCODE NO.:KPC-014-PRD-007

REVISION :00

: 21OCT 2010

UANCE : N/A

ISSUED TO

Bechtel Overseas, Inc.

N CHANNELS

PROJECT /CLIENT

aaden Aluminum Smelter

Plant Project

140


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KPC Controlled Document Integrated

1.0Title2.0Methodology

2.1General Description2.2Equipment2.3Materials2.4Preparation2.5Work & Methodology

3.0Quality Assurance3.1Contractual Requireme3.2Responsibility3.3Inspection & Testing

4.0Safety & Health4.1Protective Safety Equip4.2Environmental Safety4.3MSDS4.4Risk Assessment

5.0References6.0Figures7.0Attachments

7.1Heater Specifications7.2Thermocouple Specific7.3Forms

ERMAL AND WATER CURING OF DRAINCHANNELS AND COVER SLABS

METHOD STATEMENT

Management System

TABLE OF CONTENTS

nts

ment

Health Contractor Requirements

ations

Page 2 / 23


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1.0 TITLESteam and

2.0 SCOPE OF WORK2.1 GENERAL DESC

This docum

for Maaden Alumi

Overseas, Inc. is th

for manufacture ancompliance with th

Curing is de

temperature in con

(ACI 116R-90).

KPC will app

a. ThermalDB00-0Using R

while th

strippin

b. Water Csupple

area in t

Applicable

quoted and followe

2.2 EQUIPMENT

List of Equip

A. For1.

-

--

-


METHOD STATEMENT

Management System

ater Curing of PC Units

IPTION

nt outlines the procedure for Thermal and

um Smelter Plant Project in Jubail, Kingdom

Main Contractor and Al Kifah Precast Com

d delivery of required Precast Concrete Unitis procedure.

fined as the maintenance of satisfactory moi

crete during its early stages so that desired

ly two-stage curing system as follows:

Curing as described in Bechtel Specification

01. Thermal Curing corresponds to Acceleradiant Heat and Moisture (PCI-MNL-116, Se

e PC Units are in the mould inside the Facto

, release and lifting strength of concrete at

uring which is curing by moisture retention

ental heat. This is done after the units are t

he Stockyard.

echtel Specifications and Industry Codes pe

d.

ment:

hermal Curing

eaters / Blower (see Sec. 7.0, Attachments)

PC to use Heaters with the following specifi

Brand : Dimplex Model No. CFH90

Max. Temp. = 55CHeat Output = 9.0 kW

Noise = 60 dB

Page 3 / 23

ater Curing of PC Units

of Saudi Arabia. Bechtel

any is the sub-contractor

s and responsible for

sture content and

roperties may develop

No. 25457-0000-3PS-

ted Curing of Concrete. 4.21.3). This is done

y to achieve the required

n earlier time.

ithout the use

ansferred to designated

taining to the subject are

ations:


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-

-

-

2.3.4.5.6.7.

B. For1.2.

2.3 MATERIALSNo mate

2.4 PREPARATIONPrior app

achieved the req

3PS-DB01-0001

Time, which sho

Concrete Compr

2.5 WORK METHOA. Acceler

Curing):

1. Afteare

unif

2. Rubway

the

burl

dist

3. Cubpare

4. Mon


METHOD STATEMENT

Management System

Airflow = 900 m3/h

Throw = 10m

Temperature Control with Built-In Thermosased on settings

lectronic Surface Thermocouples, with Pins

ttachments)

adiator, Fan (for Air Circulation)

ollowcore Bed Water Heating Pipes (Option

hermometer

ubberized Tarpaulin

xpanded Polystyrene

ater Curing

essian Cloth / Burlaps

pproved Water Source

ials required.

lication of heat for thermal curing, ensure th

uired initial setting time as per Bechtel Spec

Furnishing & Delivering Ready Mix Concret

uld not be in any case less than 1 hour and a

essive Strength achieved 3.4 MPa (500 psi).

OLOGY

ted Curing of Concrete using Radiant Heat a

ensuring that the concrete has achieved th

laced and arranged in such a way that all ar

rmly (see Section 6.0, Fig. 1 & 2).

erized Tarpaulin and Expanded Polystyrene

that the units are thoroughly covered and m

ontraption. Moisture is maintained using a

p/hessian cloth. Double the thickness at co

nce of 300mm.

Samples for Compressive Tests should be c

nt concrete.itor the interior and surface temperature of

Page 4 / 23

at, Automatic Adjustment

(see Sec. 7.0,

al)

at the concrete had

ification No. 25457-0000-

Sec. 3.3 Initial Setting

s determined by the time

nd Moisture (Thermal

e initial set, the heaters

eas will be heated

to be installed in such a

inimal heat escapes from

over of moist

ners and edges for a

ured the same way as the

the unit using embedded


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ther

leas

inteinst

instr

the

redu

5. Mea6. Tem

a.b.

c

c.t

d.

e.s

t

f.c

t

c

g.t

t

h.r

(

7. Thewat

B. Water C

1. AppWat

2. Thormini

3. Dou


METHOD STATEMENT

Management System

ocouples tied to a continuous logging and

2 thermocouples (one as spare) in the locat

nal temperature is expected (generally thell thermocouples on each exposed face of t

uments at mid-point of the cover zone. As e

ehavior of the mix, the total number of sur

ced to two.

sure ambient air temperature using thermo

perature Control (see Section 6.0, Fig. 3)

re-Heat Temperature should be set at Ambi

hour (+0.33C/min).

cquire Temperature Readings every 30 min

losely monitor the differential temperature.

nit should have a temperature difference o

aintain the rate of adding 20C per hour un

he maximum allowable temperature at 65

djust the setting of heaters as necessary. A

er actual condition. Localized Hot Areas s

eating Pipes may be used to adjust the hea

ecessary

aintain the temperature at 65C and monit

ntil the required stripping and lifting streng

trength is equal to 60% of the design concre

he Materials Engineer.

llowable cooling rate is at -28C per hour (-

ontinue until the concrete temperature is n

he ambient temperature outside the enclos

racking.

emove insulation in stages in such a way th

emperature differential is not exceeded (20

emperature is within 10C of Ambient Temp

ubsequent monitoring of heating of precast

educed to every 3 hours (for Pre- and Heati

for Cooling Cycle) upon a clear demonstrati

nd other damage were incurred during first

moulds are stripped and moved to designat

r curing.

uring

oved units are transferred to designated ar

r Curing.

oughly cover individual units with pre-satur

mum of 2 layer hessian cloth.le layer polythene sheet is not required if t

Page 5 / 23

recording system. Install at

ion where the maximum

ass center). Initially,e element. Install these

perience is gained as to

ace thermocouples may be

eters.

ent Temperature +20C for

tes at this stage, and

No two portions of the

more than 20C.

til the concrete reaches

.

d or remove heaters as

ould be avoided. Bed

ing uniformity as

or every 1 hr if first time

h is achieved. Lifting

te strength as directed by

.50C/min). Cooling must

more than 22C above

re to prevent surface

t the maximum allowable

C), and until the surface

erature.

concrete units may be

g Cycle) and every 6 hours

n that no thermal cracks

3 batches of units.

d area in Stockyard for

a in the Stockyard for

ted hessian cloth. Use

e units are thermal-cured.


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4. Watconc

5.

Watthor

the

6. No c7. Wat8. Insp

dryi

9. If dr

3.0

QUALITY ASSURAN3.1 CONTRACTUAL

1. Acce000

Spec

014-

2. Becrepo

whil

3.2 RESPONSIBILIT

The foll

Procedure:

1. Ther2. Wat

Stoc

3.

InspSup

4. DocSant

5. InspEngi

3.3 INSPECTION &1. Freq

inte


METHOD STATEMENT

Management System

r used for curing must be the same water u

rete.

r is manually sprinkled until the hessian clooughly wet. Water curing will be considered

oncrete surface is damp to touch.

uring compound should be used.

r curing should be for seven (7) consecutiv

ct curing minimum twice at daytime and on

g. Replenish water as required.

ing is discovered, re-wet and increase the i

E

REQUIREMENTS

ptance criterion will be based on Bechtel Sp

-3PS-DB00-0001 Concrete Work and othe

ifications and Inspection and Test Plan Po

ITP-011.1.

tel Resident Engineer or his representative

rt on daily basis. The Bechtel Resident Engin

the inspection is being conducted.

wing personnel are responsible for the con

mal Curing: Ramesh Lama Production Engi

r Curing: Ferdinand Gurion / Eduardo Sison

kyard

ction: Alfred Comendador QC Engineer, Frvisor, Alfred Carpio QC Supervisor

ment Control and Review: Alfred Comenda

ana IMS-MR

ction and Document Review: Vinod Kannat

eer

ESTING

uency

Frequency of measurement within the un

vals specified in the Work Methodology.

Page 6 / 23

sed for the production of

h and the precast unit issatisfactory if at any time

days.

ce at night for signs of

spection frequency.

ecification No. 25457-

r relevant Bechtel

t-Pour Inspection (KPC-

ust be given a copy of

eer may also be present

uct of this Operational

neer

Production Engineer,

eddie Toledana QC

or QC Engineer, Mark

- Bechtel Resident QC

it must cover all units at


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2. Equiuse:

a.b.

usin

3. RecPoin

Co

The

W

Cal

Re

Con

to B

repr

4.0 HEALTH & SAFETY4.1 PROTECTIVE &

The followi

personnel conducti

1. Hard


METHOD STATEMENT

Management System

pment

All measuring equipment must be thorou

hermocouple must be calibrated by duly-

gency.

hermometers - must be calibrated by duly-

gency.

Heat/Blowers need not to be calibrated,

above mentioned instruments.

rds

The following Forms must be used on eac

ts:

Quality

trol Point

Form Form Code

No.

Prep

rmal Curing

Post-Pour

Inspection

Report

KPC-014-F-

QAC-034Eac

ter Curing

Post-Pour

Inspection

Report

KPC-014-F-

QAC-034Eac

ibration of

easuring

Devices

Calibration

of

Equipment

KPC-014-F-

QAC-026

Upd

re

porting of

Non-

formance /

CAPA

NC and

CAPA Log

Sheet

KPC-014-F-

QAC-032

Eac

Con

Records shall be kept in KPC QC Departm

chtel Resident Engineer duly noted by KPC

sentative.

KPC QA/QC Department copy is kept for

SAFETY EQUIPMENT

g are the list of Personal Protective Equipm

ng this activity:

Hat

Page 7 / 23

ghly inspected prior to

pproved calibration

pproved calibration

ut performance measured

h specified Quality Control

aration ITP Reference

Code

h Unit

Post-Pour

Inspection (KPC-

014-ITP-012.1)

h Unit

Post-Pour

Inspection (KPC-

014-ITP-012.1)

ated as

uired

Calibration of

Equipment (KPC-

014-ITP-014.1)

h Non-

ormity

Quality

Management

System (KPC-014-

ITP-000.1)

ent and copies distributed

C Engineer or his

inimum of two (2) years.

nt to be used by


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2. Safe3. Cott

4.2 ENVIRONMENPersonal Pr

4.3 MSDS (MANUFNot Applica

4.4 RISK ASSESSME

Not Applica

5.0 REFERENCESBechtel Specificati

Revision 00

ACI 116 R-90 Cem

American C

PO Box 909

Manual for Qualit

Products, 3rd

Editio

Precast/Pre

175 West Ja


METHOD STATEMENT

Management System

ty Shoes

on Gloves

AL SAFETY & HEALTH SUB-CONTRACTOR R

tective Equipment

CTURER SAFETY DATA SHEET)

le

NT

le

n No. 25457-0000-3PS-DB00-0001 Concret

, 07 May 2010

nt and Concrete Terminology

ncrete Institute (ACI)

, Farmington Hills, MI 48333-9094

y Control for Plants and Production of Stru

n PCI Manual MNL-116,

stressed Concrete Institute (PCI)

ckson Blvd., Chicago, Illinois 60604

Page 8 / 23

QUIREMENTS

e Work

tural Precast Concrete


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6.0 FIGURES

Fig. 1: Heater and Mould Assembl

For Drain Channels (may be modi

as per actual conditions). Note th

movement of air through direct

heater blower throw (10m) and

subsequent heat movement throu

convection.

HEATED AIR

MOVEMENT

THROUGHCONVECTION

(SAME AS ON

UPPER PORTION)

STEEL SHEET (TO

AVOID DIRECT

HEAT THROW

COLLISION BUT

TRANSFER

RADIANT HEAT)


METHOD STATEMENT

Management System

ied

gh

HEATER

HEATER

DIREC

THRO

Page 9 / 23

T HEAT

W


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0

10

20

30

40

50

60

70

80

90

100

Fig. 2: Heater and Mould Asse

heating a

Fig. 3: Thermal Curing Tempe

illustrative purposes only; ac

Pre-Heat @

+27C/hr

C

TIME Variable:

Ambient - Peak

Temp.

Time

HEATER


METHOD STATEMENT

Management System

mbly for Cover Slabs. Bed Heating Pipes are

nd temperature controlled at the Boiler Roo

rature and Concrete Compressive Strength

tual conditions may vary but must not exceedocument)

Sustained

Heating

Cooling

@ -28C/hrWater

Thermal Curing Stage

TIME Variable:

60% Conc.

Strength

TIME Variable:

Peak - Ambient

Temp.

Page 10 / 23

Concrete Strength

Curing Temperature

sed to ensure uniform

m.

elationship (Note: for

d the limits set in this

Initial Setting Time

Initial Ambient Temp.

Peak Temp. @ 65C

Conc. Lifting Strength

Curing Stage (7 Days min.)

ater Curing Stage

DIRECT HEAT

THROW

BED HEATING

PIPES


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7.0 ATTACHMENTS7.1 HEAT BLOWERS


METHOD STATEMENT

Management System Page 11 / 23


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METHOD STATEMENT



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7.2 SURFACE THERMOCOUPLE


METHOD STATEMENT



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METHOD STATEMENT



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METHOD STATEMENT



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METHOD STATEMENT



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METHOD STATEMENT



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8.0 FORMS8.1 CONCRETE POUR C8.2 POST-POUR INSPE

8.3 CALIBRATION OF E

8.4 NC AND CAPA LOG


METHOD STATEMENT

Management System

ARDTION REPORT

UIPMENT

SHEET

Page 18 / 23


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METHOD STATEMENT



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METHOD STATEMENT



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METHOD STATEMENT



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METHOD STATEMENT



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ll d d


METHOD STATEMENT

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kpc-014-prd-008_thermal and moisture curing of pc units procedure

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