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

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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:

SAES-Q-001 Concrete foundation

SAES-Q-005 Concrete foundation
SAES-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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 BI No. BI-10-01055-0006
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:
There were two (2) possible corrective actions that will be applicable on this situation .
A) By using the mechanical couplers

B) By complete removal and replacement of the damage anchor bolt

A) By Using Mechanical Couplers

1) A portion of the concrete has to be chipped out around the damaged anchor bolt in order to expose
enough of the rod to properly engage the coupler.
2) Cut off the old bolt low enough below so the replacement top section length will be at least 10 to 12 bolt
diameters.
3) Mechanical threading with a coupling nut has to be performed and shall avoid welding.

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

4) The installation of mechanical coupler may differ depending on the approved coupler requirement.
5) Grouting shall be performed as per SAES-Q-010

Samples of Anchor Bolts Using Mechanical Couplers

B) By Complete Removal and Replacement the Damaged Anchor Bolt

1) Isolate the damaged bolt by cutting the concrete around it. This is to avoid the concrete damages on non-
affected anchor bolts. When almost all of the bolts got damaged, it is advisable to re-construct the
pedestal with new 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-010

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

END OF THE METHOD STATEMENT

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