1. PURPOSE
2. SCOPE
3. REFERENCE
4. RESPONSIBILITIES
5. PROCEDURE
6. ATTACHMENT
1.0 PURPOSE
The purpose of this procedure is to provide the work methods, guidelines, and quality requirements for all structural steel and mechanical equipment foundations.
2.0 SCOPE
The scope of works covers under this procedure applies to all installation of anchor bolts for all structural steel and mechanical equipment foundations covered.
3.0 REFERENCES
SAES-Q-005 – Concrete Foundations.
SAES-M-001 – Structural Design Criteria for Non-Building Structures.
12-SAMMS-007 – Fabrication of Structural and Miscellaneous Steel.
12-SAMMS-008 – Erection of Structural and Miscellaneous Steel.
PIP STF05121 – Fabrication and Installation of Anchor Bolts.
AISC – American Institute of Steel construction – Specification for Structural Joints Using ASTM A325 or A490 Bolts.
4.0 RESPONSIBILITIES
4.1 Site Manager shall be responsible in providing all necessary requirements at site such as implementing all HSE requirements, manpower, materials and equipment to carry out anchor bolts installation activities as per schedule and as per project specification.
4.2 Quality Control Inspector shall be responsible to provide inspection documentation such as RFI Notification to SAUDI ARAMCO. Ensure that anchor bolt installation activities are being carried out in compliance with the quality requirements from materials to installation activities.
4.3 Construction Manager shall be responsible in carrying out safety measures such as preparation of barricades and warning signs, work permits, etc.
5.0 PROCEDURE
This document describes the installation procedure of Anchor bolts for all Structural Steel, Static and Rotating Equipment Foundations. The template is to be set to arrange the Anchor bolts (sleeve type), which will fix all Structural Steel, Static and Rotating Equipment, within the tolerances specified in the drawings. This setting work will be the most important step among all other works to be carried out before erection.
This setting work is carried out in parallel with the bar arrangement work of civil works. The template is fixed securely on temporary supports and then the Anchor bolts and other embedded materials are fixed on the template.
The template, Anchor bolts, etc. shall not be fixed to either the bars of the Anchor concrete or concrete molds (temporary ones).
The final concrete shall be casted without connection to the template. Scaffolding for concrete casting needs to be set in order to prevent the set anchor bolts from moving off their correct positions. Never get on the template. During concrete casting, it shall be checked and confirmed that anchor bolts and templates are set at the correct position.
When concreting is completed and the concrete’s temperature has dropped down to ambient temperature, repeat the survey.
Before the removal the templates, the centerlines shall be transferred down to the embedded plates in the concrete and retained for the use of equipment installation and survey reference.
During the removal of the templates, special care shall be taken so that the bolt threads shall not be damaged or the nuts to get lost.
5.1 ANCHOR BOLT’S SETTING ELEVATION
5.1.1 All drawing shall be referred to the latest revisions.
5.1.2 The setting elevation of the Anchor bolts before casting the concrete shall be determined in consideration of:
– Design of elevation
– Bearing (rotor) alignment
– Concrete shrinkage during curing period
5.1.3 The setting elevation of the Anchor bolts before casting the concrete shall be calculated as follows:
[Setting Elevation = Design Elevation + Bearing Alignment + Spare Height (Including Concrete Shrinkage)]
5.2 ERECTION OF STEEL FRAME TEMPLATE AND SUPPORT STRUCTURE
The erection of the template and support structure will be carried out together with the civil work. The erection Contractor shall take both mechanical & electrical work and civil work into consideration.
The steel frame template and support structure are temporary materials for setting the Anchor bolts and some embedded materials, therefore they may be modified if there is interference between support structure and embedded materials.
However, the modified position shall be reinforced at the equivalent strength.
Erection procedure for steel frame template and support structure is described at the Work Step of Foundation Bolts Setting, Para. 4
5.3 SETTING OF COLUMN SUPPORT
Column support shall be set before the first concrete casting.
5.4 ERECTION OF COLUMN, BEAM, SUPPORT and INSTALLATION of TEMPLATE
After bolting column and column support, beam and supports shall be erected in consideration of the civil works. Template is fixed provisionally to the support. Final fixing shall be done after setting the Anchor bolt.
5.5 WORK STEP OF FOUNDATION BOLTS SETTING
5.6 TABLE OF WORK STEPS
Work Step |
Notes & Caution for Work Step |
Remarks |
Reference Sketch |
| Preparation of Civil Work | N/A | N/A | N/A |
| Inspection of the receiving template | 1) Check bolt holes.
2) Confirm no distortion to the template transportation. (Tolerance: See Para. 5.1) |
*Measure *Prepare lifting equipment *Select the lifting point |
|
| Establishment of center line and elevation on foundation deck | 1) Set the “X” and “Y” axes transferred from plant basic center lines and punch the bench mark.2) Set the reference elevation on foundation deck for anchor bolt setting. | *Transit *Y-level *Measure |
|
| Setting of columns and beams for template. | 1) Mark the setting position of column-supports. Cast firs concrete and cure. (Civil work)2) Confirm position and elevation of column-support.
3) Set the column and fix on the column-support by 4) Confirm the level of beam position on columns by 5) Fix the beams to columns by welding or with gusset plates by bolting. 6) Fix the columns and beams with brace by welding if necessary.
|
*Ink pot *Level gauge *Welding machine *Transit *Y-level |
|
| Setting of template | 1) Set template temporarily to the beams.
2) Measure the distance from X and Y axes and the elevation levels from the foundation bench mark by using Piano Wire and plumb bubs in order to keep template frames in level. (Tolerance: See Para. 5.2&5.3) 3) Adjust the template in correct level by bolting and/or welding. 4) Properly reinforce the template frames with braces by welding. |
*Lifting equipment *Level gauge *Transit *Y-level *Measure *Plumb bub *Piano wire *Welding machine |
|
| Setting of embedded materials | 1) Set the embedded materials (anchor bolts, anchor blocks, jacking posts and pipe sleeves) to the template.2) Determine the elevation levels of the embedded materials. (Reference : See Para. 5.2&5.3) 3) Tack-weld the nuts to their respective square washers at three points each, after the bolts are set at proper elevation level. 4) Fix the anchor bolts, anchor blocks, jacking posts and sleeves securely to the template with nuts or by 6) Apply temporary cover to the anchor bolt sleeves, to avoid foreign materials from entering. 7) Install reinforcing materials (such as shown in the |
*Lifting equipment *Level gauge *Transit *Y-level *Welding machine *Grease |
|
| Final setting of rebar, strip and formwork for foundation | 1) Set by Civil contractor. |
|
|
| Inspection and Record | 1) When casting the concrete, check that the template dose not move off the correct position with a transit / Y- levels. | *Transit *Y-level |
|
| Curing of Concrete | 1) Cure for 4 weeks or more. |
| Inspection and Record | 1) Inspection the position and levels of the anchor bolts. (Tolerance : See Para. 5.4&5.5)2) Keep the record.
3) Compare and examine the record with that recorded before casting the concrete.
|
*Level gauge *Transit *Y-level *Measure *Plumb bub *Piano wire |
|
| Rectifying in order | 1) Remove template and beams at least 10 days after placing of concrete.2) Cut off the column unembedded in concrete by grinder.
3) Make smooth and flat on the surface. 4) Cast the concrete on the surface.
|
5.7 CHECK SHEET
Check Item |
Tolerances (mm) |
Notes and Caution |
Check Method |
| Confirmation of fabricated dimension of template | Position: ±1 Diameter: ±0.5~1.5 |
* Make the X & Y axes as for the reference. * Pay special attention to the position from the center mark. |
*Measure *Calipers |
| Confirmation of the set template | ±1 from the basing line | * Set the center marks of the template to the bench marks of the installation reference lines (X & Y axes) * Keep the right angle between the X & Y axes at ±0° (within the instrument error) |
*Transit *Measure *Plumb bub |
| Confirmation of position of anchor bolts, in X & Y axes direction. |
X and Y axes direction : ±2 Diagonal: ±4 |
* Measure the dimension from the basing lines respectively. * Check the diagonal dimension correctly. |
*Measure |
| Confirmation of elevation of anchor bolts. | Confirmation of elevation of anchor bolts. |
* Measure the levels from the referenced level respectively. | *Y-level |
| Confirmation of inclination of anchor bolts. | Within ±2 to bottom from top within 1.0/1000 |
* Measure the perpendicularity of anchor bolts. | *Precision level |