This procedure is established to stipulate for each step of test, inspection, report and assessment work of concrete mix designs at Song Hau 1 Thermal Power Plant project. It applies to all types of fresh concrete that will be used for PHC pile production (onshore part)
FOR CONSTRUCTION DOCUMENT SUBMISSION STATUS: 23/02/2016 FOR CONSTRUCTION T.V.SON T.Q.KHUONG T.V.DUNG A 12/01/2016 FOR APPROVAL T.V.SON T.Q.KHUONG T.V.DUNG REV DATE DESCRIPTION PREPARED CHECKED APPROVED PROJECT TITLE SONG HAU THERMAL POWER PLANT (2x600MW) OWNER OWNER’S CONSULTANT FICHTNER GmbH & Co KG PV ENGINEERING VIETNAM OIL AND GAS GROUP (PVN) EPC CONTRACTOR’S CONSULTANT EPC CONTRACTOR TOKYO ELECTRIC POWER INSTALLATION SERVICES VIETNAM MACHINERY COMPANY LIMITED -TEPSCO CORPORATION (LILAMA) CONTRACTOR VIỆN KHOA HỌC CÔNG NGHỆ XÂY DỰNG (IBST) VIỆN CHUYÊN NGÀNH BÊ TƠNG (ICT) PHỊNG THÍ NGHIỆM HIỆN TRƯỜNG HA NOI CONSTRUCTION CORPORATION DATE NAME PREPARED 23.02.2016 T.V.SON CHECKED 23.02.2016 T.Q.KHUONG APPROVED 23.02.2016 T.V.DUNG DOCUMENT NO SH1-HNC-P0100-C-C14-PRO-0007 SIGN (LAS XD-03) DOCUMENT TITLE Concrete mix design procedure for PHC Pile manufacture (onshore) REV No of page: 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW) TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 REFERENCES 4.0 DEFINITIONS 5.0 PROCEDURE 6.0 APPENDIXES 10 SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 1.0 PURPOSE This procedure is established to stipulate for each step of test, inspection, report and assessment work of concrete mix designs at Song Hau Thermal Power Plant project 2.0 SCOPE It applies to all types of fresh concrete that will be used for PHC pile production (onshore part) 3.0 REFERENCES - Section 6: Technical Specification for Cast in place Concrete Section 7: Technical Specification for Concrete Piling Report on detailed Design of Equipment Jetty Vietnamese standards: TCVN 7570-2006: Aggregates for concrete and mortar – Specifications TCVN 7572-2006: Aggregates for concrete and mortar – Test methods TCVN 4506-2012: Water for mixing concrete and mortar – Technical specification Other standards Foreign standards: ACI 318: Building code requirements for Structural concrete and Commentary ASTM C33: Standard specification for Concrete aggregates ASTM C150: Standard specification for Portland cement ASTM C494: Standard specification for Chemical admixtures for concrete Other standards 4.0 DEFINITIONS Owner: Song Hau Power Plant Projects Management Board (SH1PP) PMC: Project Management Consultant of Owner – Fichtner & PVE EPC Contractor: Viet Nam Machinery Installation (Lilama) Subcontractor: Hancorp A strength test: shall be the average of the strengths of three 150 by 300 mm cylinders made from the same sample of concrete and tested at 28 days A set: contains three 150 by 300 mm cylinders made from the same sample of concrete SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 5.0 PROCEDURE 5.1 Responsibilities 5.1.1 Subcontractor + To notify the related parties about plan of work implementation + To complete the appropriate check sheets or reports in progress and submit to EPC Contractor for confirmation/endorsing + To prepare the inspection document, testing equipment, etc + To carry out the testing work - The Batch Plant Manager: Is incharge of overall management of the operations of the batching plant and to be under the coordination of Civil QA/QC Manager - The Site Laboratory Manager: Is in charge of managing all laboratory activities in terms of supervising the concrete quality /ensuring that all necessary samples are taken and tests are carried out as required by the Specification and to be under the coordination of Civil QA/QC Manager 5.1.2 EPC Contractor + To prepare all the things which serve for this work + For monitoring quality related activities and endorsing check sheet/test documents at the time of the activity + For random checks to verify the Subcontractor is completing inspection forms as the work progresses + To make report, assess the results of testing of concrete mix proportion and submit to Owner/PMC for approval - Civil QA/QC Manager: Is incharge of overall quality control 5.1.3 Owner/PMC + To monitor/witness the process and EPC Contractor’s performance + To review/comment/approve on the documentation which EPC Contractor submit SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 5.2 Flowchart Sampling & Input materials tests No Testing materials at Lab Yes Input materials acceptance Yes No Proportional Design of concrete at lab Raw concrete mix proportion No Yes No Testing of concrete mix proportion at batching plant Yes Reporting 5.3 Sampling and input materials tests SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW Refer to “SH1-LLM-P0001-C-G01-ITP-0007: Inspection and test plan for concrete” 5.4 Testing materials Testing Result on Cement, Fine aggregates and coarse aggregate at laboratory 5.5 Input materials acceptance Refer to “SH1-LLM-P0001-C-G01-ITP-0007: Inspection and test plan for concrete” 5.6 Proportional Design concrete at Lab After testing Result on Cement, Fine aggregates, Coarse aggregate and Input materials acceptance, Design concrete mixing Proportion including 11 Step (Refer to “ACI 211.04R-08”): 5.6.1 Step 1: Select slump and required concrete strength 5.6.2 Step 2: Select maximum size of aggregate 5.6.3 Step 3: Select optimum coarse aggregate content 5.6.4 Step 4: Estimate mixing water and air content 5.6.5 Step 5: Select w/cm 5.6.6 Step 6: Calculate content of cementitious material 5.6.7 Step 7: Proportion basic mixture with no other cementitious material 5.6.8 Step 8: Proportion companion mixtures using silicafume 5.6.9 Step 9: Trial mixtures 5.6.10 Step 10: Adjust trial mixture proportions 5.6.11 Step 11: Select optimum mixture proportions 5.7 Raw concrete mix proportion SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW Raw concrete mix proportion is established in accordance with characteristics of input materials It shall contain detail weight/volume of individual materials for 1m of concrete and other requirements such as: water/cementitious materials ratio, slump, water absorption, module, size, type, etc Subcontractor or third party will prepare the Mix design documentation which includes the raw concrete mix proportion and submit to EPC Contractor for review 5.8 Testing of concrete mix proportion at batching plant The purpose of testing of concrete mix proportion at batching plant is to re-check the correctness of raw concrete mix proportion and verify & confirm the result of testing at laboratory Both fine aggregates and coarse aggregate at batching plant shall be tested for determining the actual moisture Base on raw concrete mix proportion, actual moisture and water absorption of aggregates, actual mix proportion after correcting moisture of aggregates can be calculated That is the proportion mixed at batching plant “C-001A-LAB-003-01-Dosage adjustment conforming to actual moisture of aggregates” form shall be used to adjust the moisture of aggregates 5.8.1 Trial mixes a) Trial mixes at the Laboratory Trial mix for each mix class shall be made using water-cementitious materials ratios depend on Raw concrete mix proportion.Concrete mix after mixing of all proportions shall be sampled to check the compressive strength.Based on the compressive strength, the propotion of concrete which meet requirement shall be selected “C-001A-LAB-006-01_Concrete test sample stamp” shall be used in this section b) Trial mixes at the batching plant Raw concrete mix proportion that were selected after trial mixes at the Laboratory will be used to trial mixes at batching plant.Concrete mix after mixing of all proportions shall be sampled to check the compressive strength.Based on the compressive strength, the propotion of concrete which meet requirement shall be selected.Mix proportions that were selected and test result will be summited to The Owner for approved “C-001A-LAB-006-01_Concrete test sample stamp” shall be used in this section SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 5.8.2 Check slump, temperature, air content & setting time of concrete mix after mixing The slump test shall be performed in accordance with ASTM C143 The temperature test shall be performed conforming to ASTM C1064 The air content test shall be performed in accordance with ASTM C231 or ASTM C173 “C-001A-LAB-003-01_Dosage adjustment conforming to actual moisture of aggregates” form shall also be used to check these parameters 5.8.3 Quantity of specimens need to be sampled at concrete age for each mix proportion - days: 01 set (for strength reference) - days: 01 set (for strength reference) - 28 days: The set used for each water-cementitious material ratio shall be “C-001A-LAB-006-01_Concrete test sample stamp” shall be used in this section 5.8.4 Assessment of compressive strength test results “C-001A-LAB-003-02_Test report for compressive strength of molded spesimens” form shall be used to check the concrete compressive strength - Specified compressive strength: fc’ - Required average compressive strength: fcr’ - Average compressive strength (of n strength tests): fcr’ shall be determined in accordance with Table 5.3.2.2 – ACI 318 as section 5.6.3.2 Specified compressive strength (MPa) Required average compressive strength (MPa) fc’ < 21 21 ≤ fc’ ≤ 35 fc’ > 35 fcr’ = fc’ + 7.0 fcr’ = fc’ + 8.3 fcr’ = 1.1fc’ + Evaluation and acceptance of concrete: Assessment shall be acceptable if two following conditions are met: SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW (*) ≥ fcr’ shall be determined as average of at least new consecutive strength tests (4 sets – 12 cylinders) (**) Strength level of an individual class of concrete shall be considered satisfactory if both of the following requirements are met: - Every arithmetic average of any three consecutive strength tests equals or exceeds fc’ - No strength test: + Falls below fc’ by more than 3.5 MPa when fc’ is 35 MPa or less + Falls below fc’ by more than 0.1*fc’ when fc’ is more than 35 MPa The mix proportions that reach best results shall be chosen to make report and submit for approval 5.9 Reporting The reporting structure shall be as follows: 5.9.1 Calibration certificates of testing and measuring equipment - Testing equipment - Measuring equipment - Minutes of laboratory of checking (if any) 5.9.2 Mill certificates and Test reports of input materials - Mill certificates and Test reports of Cement - Mill certificates and Test reports of Admixture - Test reports of Natural/River sand - Test reports of Manufactured sand (if any) - Test reports of Crushed stone - Test reports of Water 5.9.3 Mix design – Laboratory - Mix design + Moisture adjustment SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW + Compressive strength at days + Compressive strength at days + Compressive strength at 28 days - Mix design 2, etc (if any) 5.9.4 Trial mix – Field trial - Trial mix + Moisture adjustment + Compressive strength at days + Compressive strength at days + Compressive strength at 28 days - Trial mix 2, etc (if any) - Minutes of witness 5.9.5 Assessment Assessment of compressive strength test of concrete (at lab and at batching plant) shall be implemented by “C-001A-LAB-007_Calculation sheet of concrete compressive strength test” form 6.0 APPENDIXES Appendix 1: C-001A-LAB-003-01_Dosage adjustment conforming to actual moisture of aggregates (01 page) Appendix 2: C-001A-LAB-003-02_Test report for compressive strength of molded spesimens (01 page) Appendix 3: C-001A-LAB-006-01_Concrete test sample stamp (01 page) Appendix 4: C-001A-LAB-007_Calculation sheet of concrete compressive strength test (01 page) SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 10 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 11 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 12 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 13 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 14 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 7.0 MATERIALS’RE USED SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 15 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 7.1 CEMENT: SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 16 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 17 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 18 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 19 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 20 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 7.2 Chemical Admixture: SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 21 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 22 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 7.3 Mineral Admixture ( Silica fume ): SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 23 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X600MW 7.3 Fine Aggregate, Aggregate, Coarse Aggregate and Water will be updated later when we receive test result of Raw Input Material SH1-HNC-P0100-C-C14-PRO-0007 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 24 of 24 ... (2X 600 MW SH1-HNC-P0 100 -C-C14-PRO -00 07 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 19 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X 600 MW SH1-HNC-P0 100 -C-C14-PRO -00 07 CONCRETE. .. (01 page) SH1-HNC-P0 100 -C-C14-PRO -00 07 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 10 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X 600 MW SH1-HNC-P0 100 -C-C14-PRO -00 07... SH1-HNC-P0 100 -C-C14-PRO -00 07 CONCRETE MIX DESIGN PROCEDURE FOR PHC PILE MANUFACTURE (ONSHORE) Page 15 of 24 SONG HAU THERMAL POWER PLANT PROJECT (2X 600 MW 7.1 CEMENT: SH1-HNC-P0 100 -C-C14-PRO -00 07 CONCRETE