BI No.

BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-MS-CVL-076<Rev.1>

Jazan Refinery & IGCC Industrial Support Facilities

Jazan, Kingdom of Saudi Arabia

METHOD STATEMENT
RESTORING / REPLACING DAMAGED ANCHOR BOLT

SAUDI ARAMCO APPROVAL STATUS

EAE
Approved
Signature / Date Name / Designation

AL YAMAMA SUBMISSION STATUS

Description Name Designation Signature Date

Prepared by Ausencio Clores QC Supervisor 26 September, 2018

Reviewed by Moises Tabura QC Manager 26 September, 2018

Approved by Khalid Murudkar QA Manager 26 September, 2018

Approved by Eduardo Espinosa HSE Manager 26 September, 2018

Abdulrahman Al
Approved by Project Manager 26 September, 2018
Khaseeb

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 BI No. BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-MS-CVL-076<Rev.1>

Document Issue Purpose

>
√ For Approval For Information For Construction

INDEX
1 PURPOSE
2 SCOPE
3 DEFINITION
4 RESPONSIBILITIES
5 REFERENCES
6 INCIDENCE
7 PROPOSED RESTORATION
8 RESPONSIBILITIES
9 HEALTH, SAFETY and ENVIRONMENT
10 ATTACHMENTS

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 BI No. BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-MS-CVL-076<Rev.1>

I Purpose:
This procedure defines the restoration or replacement of a bended or damaged anchor bolt
intended for any structural or mechanical installations.

II Scope:
This procedure is applicable on any similar restoration or replacement works on damaged anchor
bolts within the ISFB EPC-6 project.

III Definition:
Anchor bolts- fastener used to attach objects or structures to concrete.

IV References:

DATA SHEETS SIKA GROUT 114 or SIKACRETE Non-shrink Grout by SIKA

DATA SHEETS SIKADUR-42 MP SLOW Epoxy Resin Based Grout
SATIP-Q-011 Epoxy Grout for Machinery Support
SATIP-Q-005 Concrete foundation
SATIP-Q-010 Cement Based Non-Shrink Grout for Structural and Equipment Grouting
ASTM F1554 Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield
Strength

“ASTM F1554 permits both cold and hot bending of anchor rods to form hooks;
however, bending in the threaded area can be a problem. It is recommended that
only Grade 36 rods be bent in the field and the bend limited to 45° or less. Rods up
to about 1” in diameter can be cold bent. Rods over 1” can be heated to 1,200° F
(648.89 ° C) to make bending easier. It is recommended that bending be done
using a rod bending device called a hickey. After bending, the rods should be
visually inspected for cracks. If there is concern about the tensile strength of the
anchor rod, the rod can be load tested.”
V Imcidence:
Damaged or Bended Anchor Bolt: ISFB is experiencing anchor bolts damages and bending at different severity.
A) A pedestal was installed with 12 pieces ASTM A36 anchor bolts which were intended for the lifting machine
foundation, (JIB Crane) at Building 200 (Maintenance Building – JZR) was accidentally hit by moving equipment
within the adjacent activity. Two anchor bolts was bended on the incident. One of the affected bolts was mildly bent
down (less than 45°) while the other has greater.The Bolts were put back to its upright position by applying the
procedure with reference to ASTM F1554. After the restoration of its position, both bolts were examined for
presence of any cracks through Radiographic Test (RT). It was later found that one has a crack on it (refer the
encircled location).

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-MS-CVL-076<Rev.1>

B) A similar incident happened at Building 220 (Maintenance Building – IGCC). A pedestal with 12 pieces ASTM A36
anchor bolts which were installed at a foundation intended for a lifting machine was accidentally hit by heavy
equipment moving in the area. Nine of this anchor bolts were damaged and bended.

VI Proposed Restoration:
A) Due to the degree of damages on the Anchor bolts, Removal and Replacement of Damaged Anchor Bolt will done
by the below procedure:

A-1. Incidence A
1. Isolate the damaged bolt by cutting the concrete around it. This is to avoid the concrete damages on
non-affected anchor bolts.
2. Do the chipping by an electric hammer drill. Avoid using pneumatic jack hammers as it will disturb the
other bolts. Do the chipping until the full length of the anchor bolt is exposed.
3. Remove the Anchor Bolt and enlarge the chipped portion of concrete while preventing the adjacent
anchor bolts from being disturbed. This is to give enough volume of grout during installation of new
anchor bolt.
4. Provide touch up and repair for the reinforcements prior to installation of formwork.
5. Grouting shall be performed as per SAES-Q-011- Epoxy Grout for Machinery Support (Whenever
cementitious grout will be used for the restoration, CSD approval shall be obtained when needed)

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-MS-CVL-076<Rev.1>

A-2. Incidence B

1. On severe damages of Anchor Bolt and majority of Anchor Bolts were affected, the concrete pedestal
shall be completely removed up to 100 mm from below the bottom of the anchor bolt. New anchor
bolt shall be installed and re-casted with fresh concrete.
2. Care during chipping should be done to avoid severe damaged of reinforcements.
3. The chipped surface of concrete has to be cleaned and shall be free of any loose material.
4. Touch-up the damaged coating and install the new Anchor Bolts prior to formwork installation.
5. Pedestal can be restored by casting concrete with the required mix design.

VII Responsibilities:
Site Engineer or Supervisor- Shall be responsible for the implementation of this restoration process
under the direct supervision of the Construction Managers.
Quality Manager- Shall ensure that the approved procedure is being implemented.
QC Inspectors - Shall perform monitoring during restoration process.

VIII HEALTH, SAFETY and ENVIRONMENT:

 Health, Safety and Environment issues shall be guided by AYC safety procedures and ARAMCO
Standard.
 Work area to be kept clean, safe and easily accessible
 Appropriate PPE shall be worn at all times
 Safety talk shall be conducted to remind the workers about the risk involved before commencing
the activity
 When necessary, work permits shall be secured prior to work execution

IX ATTACHMENTS
 DATA SHEETS - SIKA GROUT 114 or SIKACRETE Non-shrink Grout by SIKA
 DATA SHEETS - SIKADUR-42 MP SLOW Epoxy Resin Based Grout
 SATIP-Q-011 - Epoxy Grout for Machinery Support
 SAIC-Q-1053 / SAIC-Q-1054
 SATIP-Q-010 - Cement Based Non-Shrink Grout for Structural and Equipment Grouting
 SAIC-Q-1048 / SAIC-Q-1049

END OF THE METHOD STATEMENT

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