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DOC. NO. KOC-C-005 I Page 1 of 26 I REV. 1
. . KUWAIT .OIL COMPANY (K.S.C.)
KOC STANDARD FOR
MATERIALS AND WORKMANSHIP
SITE PREPARATION AND EARTHWORKS
DOC. NO. KOC-C-005 I FORMERL Y 0 1 H H - 1002 & KOC-DES-C-00
1)
ISSUING AUTHORITY:
STANDARDS DIVISION
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DOC. NO. KOC-C-005
KOC STANDARD FOR
MATERIALS AND WORKMANSHIP
SITE PREPARATION AND
EARTHWORKS
DOC. NO. : KOC-C-005 ( FORMERLY 015-SH- 1002 &
KOC-DES-C-001)
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DOC. NO. KOC-0005 I Page 3 of 26 I REV. 1
TABLE OF CONTENTS
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SCOPE
GENERAL I APPLICATION
TERMINOLOGY
REFERENCE CODES AND STANDARDS
ENVIRONMENTAL CONDITIONS
HEALTH, SAFETY AND ENVIRONMENT
SELECTION OF MATERIALS
BORROW PIT
REFERENCE MONUMENTS
SlTE PREPARATION WORKS
EARTHWORKS
EXCAVATION FOR SPECIFIC WORKS
BACKFILLING FOR SPECIFIC WORKS
INSPECTION AND TESTING
QUALITY ASSURANCE
DOCUMENTATION
APPENDIX- I
SlTE RECORD FOR SlTE PREPARATION & EARTHWORKS
PAGE NO.
4
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DOC. NO. KOC-0005 I Page 4 of 26 I REV. 1 SCOPE
This Standard provides the minimum requirements for materials
and workmanship associated with Site Preparation and Earthworks at
the new and 'existing KOC Facilities or within KOC operation areas
in Kuwait.
This Standard covers the extent of work as described herein but
is not limited only to the demolition, she clearance, excavation,
filling, hauling, compaction, disposal, borrow pit, dewatering,
inspection, testing and quality control etc. involved in the
Works.
Final grading and construction of bund walls are excluded from
this Standard. For details, refer KOC standards for materials and
workmanship - " Roadways, Paving and Hardstanding " ( KOC-C-024 )
and " Bund wall " ( KOC-C-033 ) which are to be issued.
GENERAL I APPLICATION
The materials and workmanship for any work described in this
document shall conform to the requirements of this Standard and the
reference standards I codes.
Any exception or deviations from this Standard, alongwith their
merits and justification, shall be brought to the attention of
KOC's Controlling Department, for their review, consideration and
amendment by Standards Division ( if required ).
TERMINOLOGY
Definitions
Contractor
Person or persons, firm or company, approved by KOC, who are
undertaking the construction work covered by this Standard.
Soil
Any natural or artificial material not classified herein as top
soil or hard strata.
Fill
Any deposits or construction which have been manmade as distinct
from geological agencies.
Gatch
Gatch is the local name of a type of calcareous soil which as a
fine to
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DOC. NO. KOC-C-005 I Page 5 of 26 I REV. 1 medium well graded
granular material exhibits good cementing properties under
compaction. It is widely used in Kuwait as a major filling
material.
3.1.5 Common Excavation . .
Excavation / cutting in any material including rock except
topsoil' and blown sand. All common excavation shall be classified
as suitable or unsuitable materials for structural fill. ",
Suitable Material
AU materials such as gravels (sizes not larger than 50mm),
graded sands, silt and nonplastic clay which are acceptable for
fill 1 backfill in accordance with the requirements of this
Standard as to compaction and soil classification.
Unsuitable Material
A perishable or combustible material, peat, muck, slurry, rocks
or any buried debris, highly sensitive plastic clay, expansive clay
that is not capable to meet the requirements of this Standard as to
compaction and soil classification.
Liquid Limit ( LL )
The moisture content (expressed as a percentage of dry mass) at
which a soil passes from the liquid to the plastic state, as
determined by the liquid limit test e.g. at which a pat of soil
placed in a standard cup of the test apparatus and cut by a groove
of standard dimensions will flow together at the base of the groove
for a distance of13 mm (112 in) when subjected to 25 shocks from
the cup being dropped 10 mm in a standard liquid limit apparatus
operated at a rate of 2 shocks per second.
Plastic Limit ( PL )
The moisture content (expressed as a percentage of dry mass) at
which a soil becomes too dry to be in a plastic condition, as
determined by the plastic limit test, e.g. at which a soil can no
longer be deformed by rolling into 3.2 mm (118 in) in diameter
threads without crumbling. Plasticity Index ( PI )
The range of moisture content over which a soil behaves
plastically. It is the numerical difference between the liquid
limit and the plastic limit of a soil e.g. PI = LL - PL
Optimum Moisture Content ( OMC )
The moisture content expressed as a percentage of dry mass ( % )
at which a specified amount of compaction will produce the maximum
dry density.
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DOC. NO. KOC-C-005 I Page 6 of 26 I REV. 1 Swelling
The expansion of a soil on reduction of pressure due to water
being drawn into the voids between particles.
Compaction
The process of packing soil particles more closely together by
rolling or by other mechanical means, thus increasing the dry
density of the soil as a consequence of removal of air from the
voids between particles.
Modified Proctor Test
The standard Proctor's Compaction test modified by the American
Association of State Highway and Transportation Officials ( AASHTO
) for greater compactbe effort. In this test (AASHTO T180), a 50 mm
diameter ramrner having a heavier mass of 4.50 kg has a free fall
of 450 mm from above the top of soil in a 105 mm dia. standard
mould of 1.0 litre volume and compacts the soil samples, sieved
through a 20 mm sieve in 5 thinner layers with the same number of
25 blows per each layer.
California Bearing Ratio
The ratio expressed as a percent ( % ) of the load required to
cause a circular piston of standard cross sectional area ( 1935
sq.mm ) to penetrate the soil from surface at a constant rate of
1.3 mm (0.05 in), to the standard load required for similar
penetration. The CBR values are obtained as a ratio between the
corrected load values for each specimen at 2.54 and 5.08 mm (0.10
and 0.20 in) penetration and the standard loads of 6.9 and 10.3 MPa
(1 000 and 1 500 psi) respectively. Abbreviations
KOC Kuwait Oil Company ( K.S.C )
HSE Health, Safety and Environment
AASHTO American Association of State Highway and Transportation
Officials
CBR California Bearing Ratio
REFERENCE CODES AND STANDARDS
In the event of conflict between this Standard and the
standardslcodes referenced herein, the most stringent requirement
shall apply, unless otherwise specified.
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DOC. NO. KOC-C-005 I Page 7 of 26 I REV. 1 I
4.2 List of standards and Codes :
The latest edition of the following standards, codes and
specifications shall apply:
International Standards and codes
Methods of Testing Aggregates
Methods of Test for Soils for Civil Engineering Purposes
- Part 2 Classification Tests
- Part 4 Compaction Related Tests
Code of Practice for Earthworks
Method for Particle - Size Analysis of Soils ASTM D 422 (AASHTO
T88)
ASTM Dl556 (AASHTO T191)
Test Method for Density of Soil in Place by the Sand Cone
Method
ASTM Dl557 Test Method for Laboratory Compaction Characteristics
of Soil Using Modified Effort
ASTM Dl883 (AASHTO T I 93)
Test Method for CBR ( California Bearing Ratio ) of Laboratory -
Compacted Soils
AASHTO TI80 Test Method for Moisture Density Relations of Soils
Using a 10 Ib Rammer and an 18 in Drop
ASTM D2487 (AASHTO M145)
Test Method for Classification of Soils for Engineering
Purposes
ASTM D4253 Test Method for Maximum lndex Density and Unit Weight
of Soils Using a Vibratory Table
ASTM D4318 (AASHTO T89 & T90)
Test Method for LSquid Limit, Plastic Limit arid Plasticity
lndex of Soils
KOC Standards
KOC-G-007 KOC Standard for Basic Design Data
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1 - DOC. NO. KOC-COO5 I Page 8 of 26 REV. 1
ENVIRONMENTAL CONDITIONS
The environment of Kuwait, is severe on all equipment and
structures and must be considered carefully before deployment of
plant and equipment. It must be assumed that, unless otherwise
specified, equipment and samples shall be protected from sand and
fine particle dust storms, satt laden winds, corrosive chemical
contaminants and extreme temperatures.
KOC Standard for Basic Design Data, KOC-G-007, provides the
detailed design information regarding the environmental, site, and
utility supply conditions prevailing throughout the KOC
facilities.
HEALTH, SAFETY AND ENVIRONMENT
The contractor shall employ all necessary health & safety
procedures to protect personnel and surrounding environment during
Site preparation and other on-site field works procedures.
All relevant safety requirements of the KOC Fire & Safety
Regulations and the KOC's HSE policy shall be strictly adhered to
for all works performed within KOC operation areas.
SELECTION OF MATERIALS
Suitable Fill Materials
Based on the geotechnicat investigation report of the project
and laboratory tests on the soil samples in conform*ky with para
14.2, the materials accumulated from the common excavation shall be
selected and classified as " suitable " for filling and compaction
in accordance with para 7.2 of this Standard and other relevant
standards mentioned herein.
In the event that such material is not acceptable due to
unsuitable characteris- tics or becomes insufficient, the
"suitable" fill materials shall be imported from an offsite, KOC
approved borrow pith), that comply with the selection criteria in
paia 7.2.
Suitable fill material shall be clean and free from highly
plastic clay, coral, oil contaminated, organic or combustible
material, excessive fines, rock and debris or other unsuitable
materials described in para 3.1.7 not capable of complying with the
compaction requirements.
The maximum particle size of fill materials shall not exceed 50
mm.
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DOC. NO. KOC-COO5 I Page 9 of 26 I REV. 1 7.2 Selection
Criteria
7.2.1 Suitable fill material shall be selected on the basis of
the following minimum properties in Table I :- ..
Table I
Group Symbd
GW
GP
SW
SM/SC
CL-ML
I Soil Group GW, GP, SW, I ASTM D 2487 SM, SC, CL-ML 1 NO= 1
I
Dry Density ( Min.) r 1.90 gm I cu.cm AASHTO T 1 91 1 ASTM D
1556
Liquid Limit ( Max. % ) S 25 AASHTO T 891 ASTM D 4318
Plasticity Index( Max.% 1 S 6 AASHTO T 901 ASTM D 431 8
Soaked CBR value at 2 12 AASHTO T 1931 95 % modified Proctor I I
ASTM D 1883 test ( T 1 8 0 ) ( Mine%) A maximum swdl (CBR) S 1
AASHTO TI93 at 95% modified Proctor I I test ( T 1801 % ) I I
Group Name
We# grsded g r a d
Poor& graded g r a d
WeJlgraded sand
Sn7ty/ Clayey sand
Lean day with silt
Group Description
SiYghty M t y or dayey Gravds l mom than 50% coarse f rsc th
retained on k. 4 &w with 5% fines < 0.06mm 1.
- same as abow -
SgM& silty or dayey sand l 50% w man, of coarse frBctrTon
passes No. 4 &ve with 5% fines e 0.06 mm I.
S t y or dayey sand l 50% or more of coarse fractlion passes No.
4&m withmore than 72% fines
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DOC. NO. KOC-GOO5 I Page 10 of 26 I REV. 1 7.2.2 Unsuitable
material shall comprise of those as defined in para 3.1.7 and
shall
generally include materials which are difficult to compact,
having liquid limit exceeding 40 as determined by AASHTO T 89
and/or plasticity index exceed- ing 11 as determined by AASHTO T
90, and salt contaminated deposits ( Sabka ).
Gatch is generally used for filling materials as road subbase,
embankments, bundwalls, under floors and paved areas and in areas
where the excavated soil is found to be unsuitable for backfilling
and proper compaction. Gatch should be of light yellow to mottled
white colour, free from organic matters and stones and shall have
the following minimum properties in Table II :-
Table II I
Soil Properties Minimum Requirements
Soil Classification Soil Group A-1-a, A-1-b, A -24 1 or Sdl
Group GW, GP, SW ,
SM . SC , CL-ML ( NO= f I Amount of Finw ( silt +clay) 1 0 %
< F < 1 5 % passing the sieve size 200 ( F = Fine Fraction
1
Dry Density (Min.) 2 1.95 gm / cu. cm Liquid Limit ( Max.% 1 S
25
Plasticity Index ( Max.% 1 S 6
Soaked CBR value at 95 % r 20 modified Proctor test ( T180 1 I
Min. % 1
/ Test Method I AASHTO M 1451 ASTM D 2487
ASTM D 422 / AASHTO T 88 AASHTO T 1911 ASTM D 1556 AASHTO T 89 1
ASTM D 4318 AASHTO T 90 I ASTM D 4318 AASHTO T 193 1 ASTM D
1883
NOTE I I ) : Refer Tabh l
Water
Brackish water in addition to fresh water shall be used for all
earthwork operations unless mentioned elsewhere or directed by KOC
to the contrary. Sea water will not be permitted to be used for any
work.
Fresh water shall be used for compaction of backfill material
within the areas covered under structural excavation or within an
area of one (1) metre from all surfaces of the structure, whichever
is the lesser.
BORROW PIT
Where KOC permits the contractor to obtain fill materials from
the approved borrow pits after ascertaining the suitability of
materials, the procedure shall be adopted as follows :-
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DOC. NO. KOC-COO5 1 Pane 11 of 26 I REV. 1
The site of the borrow pit shall be stripped of all overburden
e.g. hard rocky materials.
The overburden and all unsuitable material for filling shall be
heaped well clear of the borrow pit in an area approved by KOC.
During excavation operations , the excavated faces of the borrow
pit shall be maintaned at the natural angle of repose of the
material to prevent collapse and safeguard personnel and
equipment.
When the borrow pit is abandoned by the contractor, it shall be
backfilled with the overburden and other available material and
shall be graded to the approval of KOC.
REFERENCE MONUMENTS
Four ( 4 ) permanent reference monuments shall be constructed
preferably at the four corners of the Site or as directed by KOC
onsite and shall be protected at all times.
SITE PREPARATION WORKS
Commencement Requirements
Earthworks shall not commence until the contractor has provided
KOC with, and obtained their approval to the following :-
Work / Excavation permits
Methods of excavation
Means of support to the sides of excavation
System of dew atering
Demolition of existing surface , underground structures and
obstacles ( wherever applicable )
Moving of any existing services, pipes, culverts and the like on
the Facility or affecting the Works
Safety arrangements
The contractor shall take proper care to control dust generating
from Site operations and prevent its spread to creat a nuisance in
the surrounding area(s).
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DOC. NO. KOC-COO5 I Page 12 of 26 I REV. 1 The contractor shall
provide and erect slope stakes, profiles, templates, sight rails
and the like and properly set out the proposed work from the
baselines, levels, co-ordinates or a datum given by KOC.
The contractor shall verify all information and references (
bench marks, levels, co-ordinates, Nonh 'direction ) shown on
Contract .drawings prior to commencement of siteworks. The
contractor shall be responsible to carry out any survey work of the
Site, whenever directed by KOC and shall get approvals from KOC for
akl the drawings prepared by him.
The contractor shall verify, using aU means at his disposal
including hand excavations and lor by the use of detecting
equipment, the exact location of existing services and shall
indicate the same on the drawings. No major site works shall
commence until such drawings have been reviewed by KOC.
The contractor shall take all necessary precautions and
preventive steps as directed by KOC to protect any existing
services, drains, water and gas mains, power and telephone cables
and any other installations, from being endangered from excavations
and/or slips and falls. In case of any damage to such existing
sewices and or any other installation, it shall be made good by the
contractor at no cost to KOC whatsoever.
However, any such approval by KOC shall in no way relieve the
contractor of his responsibility for the safe and correct execution
of the work.
Demolition
The contractor shall demolish all the redundant installations,
buildings, structures and belowground obstructions within relevant
work areas in accordance with the drawings and as directed by
KOC.
The contractor shall load, haul and dispose off all the debris
resulting from the demolition work as directed by KOC to an
approved dumpyard. None of the debris shall be used as filling
within the Site.
The contractor shall carry out filling of the resultant
excavated areas for removal of belowground obstructions with
suitable material as approved by KOC.
Explosives shall not be used for any purpose on the Works.
Safety Precautions
The contractor shall provide sufficient safety signs on and
along the excavated areas. Lamps with fluid fuel shall never be
used. Hard hats and safety boots shall be provided to all working
people on any Site and even for visitors.
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DOC. NO. KOC-C-005 I Page 13 of 26 I REV. 1 Site Clearance
All work areas shall be cleared of vegetation, contaminated
soil, debris, refuse or deleterious materials and also debris from
demolition work prior to Commencing excavation or fillirig.
Wind blown sand shall be removed to a minimum depth of 300 mm or
to such depth as specified by KOC.
Work areas shall at all times be kept free from surplus
materials and rubbish.
Spoil from she clearance shall be loaded, carted away as
directed by KOC to an approved dumping area. Only the selected soil
t top soil and surface soil ) free from roots, debris and oil
contamination shall be stockpiled elsewhere on site for further use
in site landscaping and reinstatement.
Disposal of Surface Water
The contractor shall be responsible for the disposal of all
surface water as it accumulates on Site during the construction
period until such time as, in the opinion of KOC, the permanent
drainage system is completed. The contractor shall provide all
necessary drainage through open ditches, ponds, culverts, manholes,
soakways etc. as directed and approved by KOC.
Ditches and Ponds for drainage shall be cut through within the
limits of f 225 mm of the demarcated area, considering the natural
slope of the surrounding areas of the Site. The sides shall be
dressed fair throughout and bottom graded so as to carry off the
water to the outlet to be provided as instructed by KOC.
Culverts excavation shall include all excavation required for
the installation of culverts and their appurtenant structures to
the specified lines, grades and dimensions. If the materials at the
bottom of excavated level are found to be soft, they shall be
removed to the depth of reasonably hard strata and filled with
coarse granular material, levelled and compacted to the specified
grade.
Dewatering
The contractor shall be responsible to provide, if necessary, a
complete dewatering system with sufficient numbers of equipment to
keep the mats) of excavation dry and free from subsurface water and
to maintain the water table below the required formation 1
foundation levels indicated on Contract I approved drawings.
Dewatering shall be carried out continously ( if required )
without any interruption until KOC directs otherwise. Standby
equipment and necessary maintenance staff shall be available to
ensure continuous working. However,
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care shall be taken to prevent the removal of fine materials
from the surrounding ground during dewatering operations.
Prior to commencement of excavations, the contractor shall
prepare and present to KOC the detailed proposals for dewatering
the Site as necessary.
EARTHWORKS
Excavation GeneraUy
Excavation shall be performed to the lines, grades and levels
indicated on the approved drawings or as instructed by KOC. The
final levels and the prepared surfaces at the bottom of excavations
shall be checked and approved by KOC prior to commencing subsequent
Works.
Where excavation works are to be carried out by machine,
sufficient depth shall be left unexcavated to reach the exact level
by hand excavation. In the existing KOC operation areas, only hand
excavation shall be made for any work unless otherwise directed by
KOC.
Excavations, cut-and-fill areas shall be kept free of water by
pumping, temporary ditches or other approved means. The ponding of
the area shall be avoided by sloping the cut-and-fill surfaces.
Where excavation reveals a combination of suitable and
unsuitable materials, wherever it is practicable, excavations shall
be performed in such a manner that the suitable materials are
excavated separately for use in the Works without contamination by
the unsuitable materials.
Unsuitable excavated material shall be loaded and carted away as
directed by KOC, to an approved dumping area. None of this material
shall be used as filling within the Site.
Where unsuitable material is encountered in the subgrade, it
shall be removed completely to such depths and over such area as
directed by KOC. The resultant excavated area(s) shall be
backfilled with suitable borrow material deposited in layers not
exceeding 200 mm loose depth and mechanically compacted in
compliance with the requirements described in para 11.3.
Where the slopes of any cutting be over-excavated beyond the
dimensions shown on the drawings, each affected area shall be
backfilled and compacted to the required profile by the contractor
without any cost to KOC. The backfilling shall be done with
approved fill material in layers not exceeding 200 mm loose depth
and compacted ( mechanically or by hand tamping ) in the manner to
satisfy the compaction requirements in para 11.3.
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DOC. NO. KOC-C-005 1 Page 15 of 26 I REV. 1
Where excavations are taken below the general formation level
shown on the drawing, the over-excavated areas shall be backfilled
with suitable fill material in layers not exceeding 200 mm loose
depth and mechanically compacted to the required elevation in
compliance with the requirements in para 11.3.
Final excavation to grade shall be accomplished by thin cuts
with light earth- moving equipment. Finished surfaces of
excavations shall be free from particles larger than 50 mm sizes
for a depth of 200 mm and shall be sealed immediately by d i n g
with a self-propelled non-vibrating light roller.
All operations on open cut areas shall be regulated to minimize
the over- running of the areas with construction plant. Haul roads
shall be constructed in these areas as required.
Normally, the depth of open excavations shall be limited to 1.50
m without supports to the sides of excavated area. However,
depending on the nature of soil encountered at the Site and
presence of groundwater or oil contamination, the contractor shall
ensure the safety of the Works by benching of the slopes or by
providing adequate supporting arrangement to the sides for deeper
excavations.
Excavated materials shall be deposited at least 1.5 m away from
the edge of excavation. The height of the excavated material shall
be kept such as to prevent the danger of slides & slips and
consequent damages to structures, services and personnel.
Filling Generally
All fill material shall be either selected from the pile of
segregated excavated materials or imported from the approved borrow
pit and classifM as "suitable",hich shaU comply with the
requirements defined in para 7.2.
The approved material for filling over areas shall be deposited
in layers not exceeding 200 mm loose depth, watered and well
compacted by mechanical means to meet the requirements in para
11.3.
The soil having a maximum density of 1600 kg per cum and below
as determined by the modified Proctor test ( AASHTO TI80 ) shall
not be used as filling materials unless mixed with heavier soils to
achieve the minimum dry density specified in para 7.2.
The area(s) to be graded shall be properly finished to the
required elevations and surfaces shown on the drawings. The
elevation of any point, the line of any edge or centre of
earthworks shall conform to those established in the
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DOC. NO. KOC-C-005 I Page 16 of 26 I REV. 1
design I construction drawings within the construction
tolerances stated below:-
Compaction of Earthworks
Fill material used in earthworks shall be compacted to
specification by equipment suitable for that purpose.
Compaction methods to be used for the selected materials shall
be proven onsite by field trials and laboratory tests to the
complete satisfaction of KOC. The contractor shall obtain
acceptance of the method from KOC prior to commencing any
compaction work.
Foundations' & Other Critical Areas
Before filling commences, the foundation-bearing and other
critical areas shall be uniformly compacted 1 proof rolled with at
least four (4) passes of a 10-ton vibratory roller. Confined areas
shall be mechanically compacted using a vibrating plate or suitable
sized pedestrian controlled roller.
Using fresh water from a KOC approved source in accordance with
para 7.3, the fill material shall be wetted to within f 2 % of the
optimum moisture content ( OMC 1 and placed On layers of maximum
200 mm loose depth.
It shall then be compacted to at least 95% of the maximum dry
density at OMC as determined by ASTM Dl557 or AASHTO T180. Where
soil conditions dictate and as approved by KOC, ASTM D 4253 shall
be used as an alternative test method.
All in-situ material within foundation-bearing areas and at
grade supporting euipment shall have a bearing capacity at least as
good as any adjacent fill. In-situ material not meeting this
requirement shaU be removed to the extent and depth required and
shall be replaced with the approved suitable material and further
compacted as described in para 11.3.3 (c). After completion of
cut-and-fill operation, foundation-bearing and other critical areas
in both cut and fill shall be proof rolled with atleast four (4)
passes of a 10 ton vibratory roller.
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DOC. NO. KOC-C-005 I Page 17 of 26 I REV. 1 f 1 Notwithstanding
the above rolling requirements in para 1 1.3.3(e) , the
compacted surface for a depth of100 mm shall have the minimum
density as specified in para 11.3.3(c) .
Non-critical Areas .
a) Using brackish and or fresh water from a KOC approved source
in accordance with para 7.3, the fin material shall be wetted to
within f 2 % of the optimum rnobture content (OMC) and placed in
layers of maximum 200 mm loose depth.
b) Undeveloped and non-critical areas of Site after completion
of cut-fill operation shall be proof rolled with at least four (4)
passes of a 10 ton vibratory roller.
C) Notwithstanding the above rolling requirements in para 11.3.4
(b), the compacted surface for a depth of 100 mm shall have the
minimum density as 90% of the maximum dry density at OMC as
determined by ASTM D l 557 or AASHTO T180. Where soil conditions
dictate and as approved by KOC, ASTM D 4253 shall be used as an
alternative test method.
Field tests shall be conducted in accordance with para 14.3 of
this Standard to establish the conformance of the above compaction
requirements.
Disposal of Excavated Materials
Excavated materials designated as "suitable " for filling and
backfilling shall be stored nearer the excavation for immediate use
or stockpiled judiciously elsewhere for later use as directed by
KOC.
Materials designated as "surplus " or segregated as " unsuitable
" for filling and backfilling shall be removed and disposed off to
the approved dumpyard.
In no case, the contractor will be allowed extra payment for
establishing temporary storage piles of materials suitable for
fill, or for any multiple handling in filling, backfilling or
disposing of excavated materials. No excavated materials shall be
removed from within the boundaries of Site, nor shall excavated
materials be used, without the approval of KOC.
EXCAVATION FOR SPECIFIC WORKS
Temporary Supports
In addition to the compliance of relevant requirements described
in paras 10.1 8t11.1 and KOC Fire & Safety regulations, the
contractor shall be responsible for the design, supply, fixing and
removal of all planking, shoring, strutting and
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DOC. NO. KOC-GOO5 I Page 18 of 26 I REV. 1 or sheet piling
required to provide safe and adequate support to the sides and
slopes of excavation.
The contractor shall consider the geotechnical nature of ground
to be excavated, the presence of ground water table, any chemical
or oil contamination. the proximity of adjacent structures and any
other relevant information in this regard for the safe design.
If, in the opinion of KOC, the material supplied by the
contractor is not of acceptable quality or of insufficient sixe or
the supporting arrangement is deemed to be not sound enough to
prevent collapse and cave-in of the sides of excavation deeper than
1.50 m, the contractor shall upon notice from KOC to that effect,
rectify the situation to the full satisfaction of KOC and ensure
the safety of Works and the adjacent structures. Planking, shoring,
strutting, sheet piles and other supports used in excavations to
maintain the stability of side walls and slopes of the excavated
area(s) shall be removed gradually with the progress of backfilling
until completed. No temporary supports shall be left in the
ground.
Foundations
All excavations shall be kept free from water accumulation so
that the Works or part thereof can be constructed in dry
conditions. Temporary deployment of pumps of suitable capacity,
associated equipment and disposal of water offsite shall be
arranged by the contractor to achieve this condition without any
cost to KOC. If required at Site, dewatering as described in para
10.6 shall be used with the approval from KOC without any adverse
affect to other structures or services.
Where excavations are cut vertically and not supported, they
shall be backfilled as soon as practicable. Supporn to sides of
excavations shall be provided wherever directed by KOC.
Where excavation for foundations is made below the foundation
level shown on the drawings, the over excavated areas shall be
filled with concrete grade of C15 having 15 N/sq.mm as
characteristics strength at 28 days to the required level.
Bottom of all excavations, filling or existing ground surface
shall be levelled and well rammed to receive the permanent Works
(concrete foundations, beds or pavings) and shall not be kept
exposed for more than three (3) days without laying blinding
concrete, polythene membrane or any other protective cover
mentioned on the drawings or as instructed by KOc. In case of
cohesive soils, this exposure of the excavated formation level
shall be limited to one (1) day only.
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DOC. NO. KOC-C-005 I Page 19 of 26 I REV. 1 Any soft spots or
pockets of unsuitable material at the foundation level or where the
material at the bottom of final excavated level becomes unsuitable
either due to exposure of weather conditions / water or due to
lapse of considerable time between excavation and subsequent Works,
it shall be removed completely and replaced with concrete grade of
C15 or with compacted fill of approved materials, as the case may
be, in compliance with instructions by KOC.
Trenches
Trenches for pipelines, drain pipes and the like which are to be
laid to line and level shall be excavated to the proper gradients
as shown on the drawings, or as instructed by KOC.
In KOC operation areas, excavation shall be carried out by hand
within 3.0 m either side of pipework, cables or the like.
No work shall proceed within 9.0 m either side of an overhead
power cable until permitted in writing by KOC.
Trenching in residential or industrial areas shall not exceed
more than 300m in length until laying of pipes or cables
commences.
Where other services are encountered, they shall be properly
supported and protected including reinstating disturbed work,
covers or similar protection, upon completion of the new work.
Continous access for vehicular traffic shall be maintained at
all road crossings by laying temporary bridges and / or by
backfilling trenches as instructed by KOC.
Trench excavations for all pipes ( except stoneware sewer pipes
laid over concrete beds ) shall be taken down to the extra depths,
backfilled with fine sandy material and consolidated to provide
continous bearing of pipe throughout the length as follows :-
a) 75 mm extra excavation and backfillig for pipe diameters upto
f 50 mm. b) 100 mm extra excavation and backfilling for pipe
diameters exceeding
150 mm but upto 300 mm.
C) 150 mm extra excavation and backfilling for pipe diameters
exceeding 300 mm.
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DOC. NO. KOC-C-005 I Page 20 of 26 I REV. 1 BACKFILLING FOR
SPECIFIC WORKS
Filling Around Foundations
Backfilling shall be carried out only after the foundations and
works upto ground level have been inspected & approved and
permission to commence the backfilling has been given by KOC.
In no case, backfilling will commence before expiry of seven (7)
days after completion of that part of foundation or structure
against which backfill is to be placed.
Backfill material free from boulders, concrete lumps and any
other foreign matter shall norrnaUy be the materials obtained from
the excavated areas. However, only material designated as "
suitable a in compliance with para 7.2 and para 11.1.4 shall be
placed in layers not exceeding 150mm and compacted evenly around
the foundations, walls, columns and grade beams etc. by hand or
mechanical rammers upto original ground level to achieve 95% of
maximum dry density at OMC.
Wherever possible, mechanical compaction shall be used in
accordance with para 1 1.3 for structural fill.
Proper care shall be taken during backfill operations to prevent
any damage to the permanent Works. In particular, damage to
protective membranes1 coatings shall be repaired before backfill is
continued.
Filling Under Floors
Clean, inert, predominantly sandy material shall be used as "
suirable fill " to the specified thickness under floors as
indicated on the drawings.
Such material shall be deposited in layers not exceeding 150mm
thick,watered and weU compacted with hand or mechanical rammers to
achieve 95% of maximum dry density at OMC.
Filling In Pipe Trenches
Backfill material in pipe trenches shall be free from stones
larger than 50mm sizes, gravels or any other hard materials which
can cause damages to pipe or corrosion protective coatings over the
pipes.
Backfilling over pipes shall be left at joints to make them free
for inspection during testing.
Backfilling shall be completed after testing of pipes and shall
be compacted by
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DOC. NO. KOC-C-005 I Page 21 of 26 I REV. 1
hand rammers to a depth of not less than 450 mm above crown of
the pipe. - The remaining part of the depth shall be backfilled by
hand or machine, well
compacted in layers of 150 mm and finished to a height of 150 mm
above surrounding ground levels.
Pipes passing through a rock formation shall be encased in
approved sandy material to a depth not less than 450 mm above crown
of pipe.
INSPECTION AND TESTING
General Requirements
KOC shall have the right to inspect at all times any tools,
equipment , materials and workmanship involved in the Site
Preparation and Earthworks to ensure compliance of this
Standard.
The contractor shall perform at aU stages of Works all the
inspections and appropriate tests that are necessary to assure that
the materials used as fill or backfill, placement and compaction
procedures meet the requirements of this Standard.
Testing
All the required tests shall be conducted on the materials by
the contractor through an independent and reputed test laboratory,
approved by KOC.
The appropriate tests shall be performed on every fwe (5)
samples, randomly collected from each source of material to be used
as fill I backfill, which are either selected from excavations /
surplus stockpiles at Site or imported from offsite borrow pit, to
estabtish the acceptibility as per Table Ill below :-
Table Ill
SI. No. 1
2
3
Tests For Soil Properties Soil Classification
4
Test Method Designation ASTM D2487 I AASHTO M I 45
Particle Size Grading ( Sieve Analysis ) Maximum Dry Density
&
5
I ( Ratio ( CBR ) 1 or BS 1377(Part4) I
or BS l377(Par t2 ) ASTM 0422 / AASHTO T88 or BS 1377(Part2)
ASTM 01 557 1 AASHTO TI80
Optimum Moisture Content Liquid Limit
6
or BS 1377 ( Part 4 ) ASTM D4318 I AASHTO T89
Plasticity Index or BS 1377 ( Part 2 ) ASTM 0431 8 1 AASHTO T90
'
Soaked California Bearing or BS 1377(Part2) ASTM D l 883 I
AASHTO TI93
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DOC. NO. KOC-0005 I Page 22 of 26 I REV. 1 These tests shall be
conducted as and when the source of material changes or the
material itself seems to be different within the Site and shall be
carried out periodically to ensure qual i i control at Site in
compliance with the instructions .of KOC.
In case, the materials fail to &nforrn to the selection
criteria in para 7.2, the contractor shall arrange the ahernative
source and carry out all the above tests on the new samples at his
own expense until KOC is fully satisfied with the acceptibility of
the material.
Field Density & Frequency of Tests
Within the foundation-bearing and other critical area(s) of the
Facility, not less than one (1) fmM in-place density test shall be
performed in accordance with ASTM Dl556 or AASHTO TI91 for every
250 sq. metres of proof rolled surfaces per layer of compacted fill
to satisfy the compaction equivalent in para 1 1.3.3 (c). Within
undeveloped and non-critical area(s) of Site, not less than one (1)
field in-place density test shall be performed in accordance with
ASTM Dl556 or AASHTO TI91 for every 1000 sq. metres of proof rolled
surfaces per layer of compacted fill to satisfy the compaction
equivalent in para 11.3.4 (c). Field in-place density tests shall
be carried out at bottom of excavations for individual
foundations.
In the event, the test results indicate the substandard
conditions that either the fill materials used do not meet the
selection criteria in para 7.2 of this Standard or the field
compaction does not satisfy the requirements in para1 1.3 of this
Standard, the contractor shall inform KOC immediately to determine
the necessary corrective measures. All corrective measures as
directed by KOC shall be implemented at the contractor's expense
and without any cost to KOC whatsoever.
QUALITY ASSURANCE
The contractor shall operate quality system to ensure that the
requirements of this Standard are achieved. The quality system
shall preferably be based on IS0 9000 series of standards and
contractor shall demonstrate compliance by providing a copy of the
accredited certificate or contractor's quality manual. Verification
of contractor's quality system is normally part of the pre-
qualification procedure, and is therefore not detailed in the core
text of this Standard.
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DOC. NO. KOC-C-005 I Page 23 of 26 I REV. 1
Generat
All correspondence, drawings, instructions, data sheets, test
results, or any other written information shall be in English
language.
All dimensions, units of measurement, physical constants, etc.
shall be in SI units, unless otherwise specified.
Work Records and Reports
The contractor shall operate a detailed recording and reporting
system on all aspects of site preparation and earthworks including
inspections and testing. All relevant information shall be set out
on a Site Record for Site Preparation & Earthworks within 48
hours of carrying out a specific work. A sample of this Site record
is shown in the Appendix I and shall be submitted in duplicate.
All test results of soil samples shall be submitted to KOC for
review and approval within 24 hours of completion of tests.
All field test results shall be reported to KOC for review and
acceptance within 24 hours of completion of tests.
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DOC. NO. KOC-COO5 I Page 24 of 26 I REV. 1 1 APPENDIX - I
17.0 SITE RECORD FOR SITE PREPARATION & EARTHWORKS
Prepared by ................................... Checked by
............................ Date .................... Project No
..................................... Contract No.
............................................................
Contractor's Name
...................................................................
Location ........................... KOC Drawing No.
.......................... Type of Work : 0 Site Preparation 0
Earthwork
................ Date of Commencement .................... Time
AM/ PM Temperature .............. Oc
................ Date of Completion ..........................
Time AM I PM Temperature .............. Oc
A. Site Preparation Details
A 1 Commencement Requirements
Work I Excavation Permit obtained 0 Yes 0 No Give reasons ( if
No
Approvals obtained ( as per clause 10.1 .I 1 Give reasons ( if
Not 1
A.2 Drawings Site Information Any Discrepancy found Elaborate (
if yes 1
A.3 Existing Sewices encountered Give details ( if yes 1
A.4 Demolition required Give details ( if yes 1
A.5 Site Clearance Give reasons for delay
A.6 Dewatering required Give details ( if y w 1
0 Not Started 0 Started 0 Completed 0 Not Completed
0 Checked 0 Not Checked 0 Partially Checked OYes O N o
OYes O N o
...................................................................................
OYes O N o
.....................................................................................
0 Not Started 0 Started 0 Completed 0 Not Completed
.............................................................................................
0 Yes 0 No
...........................................................................................
B. Earthworks Details
B.l General Areas 0 Cut 0 fill Approx. areas in cut
...................................................... sq.m Approx.
areas in fill
........................................................ sq.m
Borrow Pit required OYes O N o Bomw Pit (if yes 1 0 Selected 0
Not Selected
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DOC. NO. KOC-0005 I Page 25 of 26 I REV. 1
SlTE RECORD FOR SlTE PREPARATION & EARTHWORKS ( contd. )
8.2 General Excavation
Depth ( D in metres 1
Benching required Vertical cuts required Temporary supports
required
Any over-excavation Give reasons ( if yes 1
8.3 Fill Materials
Excavated Materials ( by visual inspection 1
Soil samples tested from
Laboratory Test results ( as per clause 14.2.2 1
Suitable Materials
Materials selected from Soil type to be used as Fill
8.4 Compaction
Type of Equipment used
Compaction by Field Trials
O
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DOC. NO. KOGC-005 I Page 26 of 26 I REV. 1 I
SlTE RECORD FOR SlTE PREPARATION & EARTHWORKS ( contd. )
C.4 Filling of over-excavated areab) 0 By Concrete 0 By
Compacted Fill
C.5 Backfilling in layen ( 150/200mrn 1 0 Yes 0 No Give reasons
( if No 1
................................................................................
C.6 Compaction Equipment used
..................................................................................
Compaction achieved O Y e s O N o Give reasons ( if No 1
..................................................................................
D. Inspection & Testing
D. 1 Inspection Frequency 0 Daily 0 Weekly Observations recorded
.....................................................................................
D.2 Field In-Place Density tests done 0 Yes 0 No ( as per clause
14.3 1
D.3 Field results 4 as per clause 11.3 1 0 Acceptable 0 Not
Acceptable
D.4 Corrective measures taken
......................................................................................
( if not acceptable
Recorded By : Approved By :
Name ........................................... Name
................................................
Signature ....................................... Signature
..........................................
REMARKS :