A07 Za e 7002586 - Baa - D

PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
JOB
PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2
SUBCONTRACTOR
NSH CORP.
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
A07-NSH-MS-CVL-0015A
SH. 1 OF 17
REV. D
SUBCONTRACTOR CONTRACT NO.

975964
SUBCONTRACTOR PROJECT NO
240832
METHOD STATEMENT
for
REPAIR OF DAMAGE ANCHOR BOLT
(TRAIN-3 PEDESTAL PR7301 GRID-1/BB)
CONTRACT NO. 6600033161

B.I.-10-01525-0002
ISSUED FOR APPROVAL
RAMIL
ENGINEERING
ASHOKAN
CONST MANAGER
MOHANAN CM
RAJEEV GEORGE
PROJECT DIRECTOR
9/11/2016
ISSUED FOR APPROVAL
RAMIL
ENGINEERING
ASHOKAN
CONST MANAGER
MOHANAN CM
RAJEEV GEORGE
PROJECT DIRECTOR
22/08/2016
ISSUED FOR APPROVAL
RAMIL
ENGINEERING
ASHOKAN
CONST MANAGER
MOHANAN CM
RAJEEV GEORGE
PROJECT DIRECTOR
17/08/2016
ISSUED FOR REVIEW
RAMIL
ENGINEERING
ASHOKAN
CONST MANAGER
MOHANAN CM
HSE MANAGER
RAJEEV GEORGE
PROJECT DIRECTOR
30-07-2016
Rev.
Description
Prepared by
Checked by
Reviewed by
Approved by
Date
HSE MANAGER
HSE MANAGER
HSE MANAGER
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 2 OF 17
REV. D

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CONTENTS
1.
PURPOSE
2.
SCOPE
3.
DEFINITIONS
4.
REFERENCE
5.
RESPONSIBILITIES
6.
TOOLS & EQUIPMENT AND REQUIRED PERSONNEL
7.
REPAIR MATERIALS
8.
EVALUATION
9.
CONSTRUCTION METHODOLOGY AND SEQUENCE
10.
QUALITY CONTROL & QUALITY ASSURANCE
11.
HEALTH, SAFETY & ENVIRONMENT
12.
ATTACHMENTS
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 3 OF 17
REV. D

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1. PURPOSE
This dedicated Method Statement describes the sequence of operation and precautions to
be observed to ensure anchor rod repair/concrete repair will be accomplish satisfactorily in
safe & acceptable manner. Anchor bolt repair work shall be performed in accordance with
AISC Design Guide 1 (Base Plate and Anchor Rod Design) in-line with approved IFC
Drawings and General Arrangement Drawings, Manufacturers Manuals, Saudi Aramco
Construction Safety Manual, and documents listed in Section 4 - REFERENCE.
2. SCOPE
This work procedure is applicable to the repair of one bend anchor rod (Train-3 Pedestal
PR7301 Grid-2, BB) accidentally bend by truck maneuvering on the area located at A07 Gasification Sulfur Recovery Unit (G-SRU) - EPC Package 2, at Jazan Integrated Gas
Combined Cycle Project (JIGCC), Saudi Arabia.
3. DEFINITIONS
CLIENT
SAUDI ARAMCO OIL COMPANY
PROJECT
IGCC PROJECT
CONTRACTOR
SNAMPROGETTI SAUDI ARABIA
SUB-CONTRACTOR
NASSER S. AL-HAJRI CORP. (NSH)
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 4 OF 17
REV. D

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4. REFERENCE
SACSM
Saudi Aramco Construction Safety Manual
SAER-5803
Concrete Repair Manual
SAES-H-003
Protective Coating for Industrial Concrete Structure
SAES-Q-001
Criteria for Design and Construction of Concrete

Structures
AISC Guide 1
Base Plate and Anchor Rod Design
ACI 347
Guide to Formwork for Concrete
ACI SP-4
Formwork for Concrete
ACI 308-92
Standard Practice for Curing Concrete.
ACI 504-82
Guide to Sealing Joints in Concrete Structures.
ASTM A36/A36M
Standard Specification for Carbon Structural Steel
ASTM F1554
Anchor bolts, Steel, 36, 55 and 105 ksi yield strength
APCS-10
Koppers Super Service Black 30255

Bituminous Black
A07-ZA-E-7002107_BAA
MS for Concrete Repair works
A00-ZA-E-0002103_BAA
MS for Application of Protective Coating on

Concrete
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 5 OF 17
REV. D
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A07-Q-VA-364403-003_00A :
Train-3 Foundation Plan Part-3
A07-Q-VA-247083-001_00B :
A07-PR-7301 Single Foundation F & R
990-Q-AA-036322-001_08
Anchor Bolt Details Inch & Metric Sizes
5. RESPONSIBILITIES
5.1
CIVIL SUPERINTENDENT Shall be responsible for monitoring of Repair of

Anchor Bolt in accordance with the procedure set in this method statement
and in compliance with applicable project specifications.
5.2
FABRICATION SUPERVISOR & FOREMAN Shall be responsible for the

safe operation and quality of the work must be done in accordance to
applicable project specifications and approved method statement.
5.3
QC MANAGER Shall be responsible for the assurances of quality

procedures are implemented and quality requirements are fulfilled.
5.4
QC INSPECTOR shall be responsible for all necessary inspection to be

performed in accordance with set of applicable project specifications and
procedures for repairing of anchor bolts.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
JOB
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 6 OF 17
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975964
6.2
TOOLS & EQUIPMENT:
Power Jack hammer
Hickey or Equivalent Bar Bender
Heating Blowtorch
Temperature Monitoring Device
Concrete Chisel
Hammer
Wire Brush
Metal Trowel
Wooden or Rubber Float
Grinder with Diamond Blade
PERSONNEL:
Site Engineer
Foreman
Steel Worker
Masons
Helpers
Safety Officer
QC Inspector
A07
DOC NO.
6. TOOLS & EQUIPMENTS AND REQUIRED PERSONNEL

6.1
UNIT
240832
240832
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 7 OF 17
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7. REPAIR MATERIALS
7.1
Anchor Rod and concrete repair shall not be performed without prior
approval of Saudi Aramco. Contractor/Subcontractor shall submit the repair
procedure complete with technical and material performance specifications,
repair drawings, list of repair materials and their datasheets for Saudi
Aramco review and approval.
7.2
Repair of structures component essential not only to utilize them for their
intended service-life but also to ensure the safety and service/ability of the
associated components.
A good repair restore the function and
performance of the structure, strength and stiffness, enhances the

appearance and alignment of the Anchor rod & appearance of concrete
surface
7.3
Repair of Anchor Rod component requires appropriate Strategies,

Techniques and expert personnel to performed and order to restore the
proper alignment of anchor. The Selected repair materials must be certain to
restore the physical appearance and durability properties of the Anchor Rod.
7.4
Approved touch-up material from HEMPEL GALVOCOAT 16380 shall be

applied to the Anchor rod after final inspection. See attached technical data
sheet/specification from Hempel paints.
7.5
Repair for chipped/broken edge concrete shall be performed using approved

grouting materials and bonding agent. SIKACRETE 114 / SIKA WELL S-2.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
JOB
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
UNIT
240832

975964
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
SH. 8 OF 17
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8. EVALUATION
8.1
Prior to execution of this procedure, all relevant field investigation and

verification are to be evaluated by Contractor Engineering and Project Quality
Management. The following shall be verified:
8.1.1 Root cause of damaged
8.1.2
Applicable solution and method statement for damaged
8.1.3 Availability of materials

8.1.4 Based on the evaluation, repair proposal will be discussed in
accordance with the degree of misalignment or damage on the anchor
bolt.
8.1.5 After confirmation, the rectification can then be executed as per
procedure outlined.
8.1.6 Inspection and survey report shall be as per Saudi Aramco Repair
Procedure
where
preliminary
and
detailed
assessment are submitted or review and approval.

9. CONSTRUCTION METHODOLOGY & SEQUENCE
site
and
damage
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
JOB
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
9.1
UNIT
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A07
DOC NO.
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NSH DOC NO.
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MISALIGNMENT AFTER CONCRETE POURING:

9.1.1
REPAIRING FOR MISALIGNED ANCHOR BOLTS BY CHAIN PULLER:

9.1.1.1
Identify the anchor bolts that are out of the tolerances through
field/site survey report.
9.1.1.2
Mark up these anchor bolts subject with rectification with a marker

to identify the correct positioned.
9.1.1.3
If necessary, chip off concrete to reach the undeformed and plumb

anchor bolt rod. The minimum depth of chipping concrete is until it
reaches the solid part of concrete.
9.1.1.4
Proper care must be observed at all times not to directly pointing

the chipping rod on the FBE rebars to avoid damage during
chipping of concrete.
9.1.1.5
Set up portable manual hoist puller tied between the support

foundations where the misaligned anchor bolt is located and
existing adjacent foundation by using wire rope. A block of concrete
shall be provided as support.
9.1.1.6
Anchor bolt shall be protected by using a rubber cloth or nylon

strap to avoid damage during process of pulling.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
9.1.1.7
JOB
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
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Repair of chipped-off concrete to follow the project approved MOS

for concrete repair A07-ZA-E-7002107_BAA.
9.1.1.8
Prior to pulling of anchor bolt to its required vertical alignment, all

member of the team shall be aware of the scope of activities to be
performed.
9.1.1.9
Surveyor shall establish a control point for alignment that will serve
as the limit for anchor bolt movement. Full time monitoring when
pulling the anchor bolt by chain puller.
9.1.1.10 During the course of rectifying the anchor bolts misalignment, the
surveyor shall monitor the vertical plumbness if already achieved
using survey instrument.
9.1.1.11 Pulling of anchor bolt shall be done as slow as possible to avoid
any possible damage to the anchor bolt rod.
9.1.1.12 After achieving the required alignment and verified by surveyor, the
work shall be verified and confirmed by designated S/C QC
inspector.
9.1.1.13 After anchor bolts are aligned as per the required vertical
plumbness, testing can proceed to verify the anchor bolts surface
for any cracks or damage by using Dye Penetrant Testing to be
conducted by qualified NDT technician and also to verify if the
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
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NSH DOC NO.
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coating is damage and if damage it will also include the application

of coating with specific approved coating material or using APCS1C as per SAES-H-101.
9.1.1.14 The testing shall be witness by Contractor QC and will confirm the
acceptability based on the report of NDT technician and after the
NDT & Coating verification and acceptance, it will be include also
the repairing of chipped out concrete using the specific approved
grouting materials depends of the volume and thickness of repair.
9.1.1.15 At the end of repair procedure for misaligned anchor bolts which
will be pulled for re-alignment, soundness of the anchor bolt should
be checked by using Ultrasonic Metal Flaw Detection. Since no
tension is expected during the design load case combination, no
pull test is required.
9.1.1.16 Contractor Engineering verified that the tension stress are not
affecting in the design load combination provided in the structural
load calculation of the specified anchor bolt.
9.2
MISALIGNMENT DUE TO ACCIDENTAL HIT BY HEAVY EQUIPMENT (A07-PR7301; GRID LINE 1 / BB)
9.2.1
REPAIRING OF BENT ANCHOR BOLT BY CUTTING & WELDING
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
9.2.1.1
JOB
UNIT
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DOC NO.
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NSH DOC NO.
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Chipping the concrete in to depth such as it reach the undeformed

and uncracked concrete section at depth plumbed anchor rod and
removed the damaged concrete by cutting.
9.2.1.2
Cutting damaged concrete by using electric hand drill / grinder and

flat chisel tools.
9.2.1.3
The limit of these repair method will be fixed at one half of the
effective depth (0.5 * Hef), should the bending length portion be
longer than the effective depth, and then anchor bolt shall be
replaced.
9.2.1.3.1
Effective depth (Hef) of anchor bolt shall be taken as

per IFC drawing. It shall be measured from top of
concrete (TOC) to bottom of anchor rod. Hef = 1045
9.2.1.4
The
qualification/pre-qualification
of
the
steel
and
welding
procedure shall be as per ASW D1.1 in compliance with A07-NSHWPS-STR-001 SMAW. Two ways of pre-qualification welding
procedures are Single-bevel-groove weld and Double-bevelgroove weld. Approved Class A welder shall be employed to do
welding.
9.2.1.4.1
Double Bevel Groove Weld shall be used to repair

damage anchor bolt as per AISC Steel Design
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
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Guide for Base Plate and Anchor Rod Design.

Section 2.11.3 Anchor Bolt Repair.
9.2.1.5
Welding a piece of threaded rod (ASTM A36) with the length as per
site conditioned.
9.2.1.6
In order to restore into initial configuration, anchor bolt projection

must be design as per the IFC drawing. A ring of washer is made
from ASTM A36 shall be positioned on top surface so that it will
flush with the existing anchor rod. When the welding is complete,
the ring plate attached on top surface can be removed from the
anchor rod. Finally, the weld can be ground flush around the
surface of the anchor rod.
9.2.1.7
Post welding visual inspection and Dye Penetrant Testing should

be carried out to the acceptance of the welding.
9.2.1.8
In conformity to Project Specification AISC design guides listed in

section 3.1. Pre-qualified CJP welding will be carried out and tested.
9.2.1.9
Repairing of galvanized coated materials of anchor bolt shall be as

per 12-SAMSS-007. Damaged galvanized coated shall be repair in
accordance with ASTM A780/780M with organic zinc rich coating,
approved under APCS-1C and the type of coating is ZINC-RICH
Epoxy primer OR Equivalent approved materials.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
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NSH DOC NO.
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9.2.1.10 Anchor bolt shall be check by survey for alignment, plumbness and
elevation. S/C QC shall verify the survey report for acceptance.
9.2.1.11 Preparing the repair of concrete by providing formworks on chipped
out concrete using approved concrete grout materials that will
depends on the volume and thickness of concrete repair.
9.2.1.12 Pouring of grout shall be as per its manufacturer recommendation.
Use non-shrink cementitious grout as per SAES-Q-010.
9.3
Repair of chipped/broken edged concrete as a result of accidental collision by heavy

truck / equipment.
9.3.1
Mark straight line on cracked concrete surface as guide for grinding/cutting.
9.3.2
Chipped broken edged of concrete, makes a straight and plan level surface.
Refer to attached sketch plan drawing.
9.3.3
Clean the concrete surface. Remove dust and loose particle by using air
blowing or water flushing.
9.3.4
Retouch damaged coated in rebar using approved touch up paint

POLYGUARD 85 ME.
9.3.5
Provide sides formworks. Ensure tightness by sealing the sides and gaps
using multi purposed sealant.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
9.3.6

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Substrate concrete surface shall be thoroughly soaked with clean water (at
least 24 hour). Remove excess pounding water prior to application of one
coat of approve bonding agent SIKAWELL S-2 and scrubbing it well into the
surface.
9.3.7
Provide plastic sheet cover protection on exposed part of anchor bolt prior to
grouting / pouring.
9.3.8
Once the applied bonding agent becomes tacky into concrete surface, pour
mixed fresh grout micro-concrete SIKACRETE 114 up to the same TOC level.
9.3.9
Clean excess grout materials and provide protection from excessive

temperature (Thermal / Shrinkage Cracks) by covering the newly grouted
surface using polyethylene/plastic sheet.
9.3.10 Continues water curing is required for at least 7 days.
10.
QAULITY CONTROL & QUALITY ASSURANCE

10.1 All stages of work shall be inspected in accordance with the reference mention in
section 4
10.2 Materials receiving inspection shall be done for reviewed and approval, prior to
use. All materials shall be compliance with ASTM or ACI requirements and
approved by Snamprogetti / and Saudi Aramco.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
JOB
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.
UNIT
240832
A07
DOC NO.
A07-ZA-E-7002586_BAA
NSH DOC NO.
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10.3 Only qualified NSH repair crews shall performed the straightening of anchor rod
and do the repair in concrete. Manufacturers technical support can be obtained
on initial application of approved products to ensure proper use.
10.4 Prior to performing any repair works, the repairing activities shall be coordinated
with NSH QA/QC personnel.
10.5 Documentation, Inspection & Testing records and reports shall be as per
documents listed in Section 4.0 "REFERENCES" and as per SATIP (Saudi
Aramco Typical Inspection Plans), SAIC (Saudi Aramco Inspection Checklists)
and SATR (Saudi Aramco Test Report).
10.6 Contractor/Sub-contractor shall comply with all mandatory Saudi Aramco
Engineering
requirements
(MSAERs),
project
specifications
and
Quality
procedures. In case of conflict between above standards, most stringent

requirements shall govern.
11.
HEALTH, SAFETY & ENVIROLMENT

11.1 The work shall be executed in accordance with the approved Safety Plan.
11.2 Before starting the work, this work procedure shall be discussed to all personnel
involved.
11.3 Responsible supervisor will monitor all activities during the construction
11.4 Tool Box Talks to be done at the start of each work.
PLANT LOCATION
JAZAN SAUDI ARABIA
CUSTOMER
SAUDI ARAMCO
PROJECT / UNIT
SUBCONTRACTOR
NSH CORP.

975964
JOB
UNIT
240832
A07
DOC NO.
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11.5 PPEs safety protection such as wearing of safety helmets, sturdy leather steel toe
cap shoes and eye protection while on site in the execution of work is mandatory.
11.6 MSDS shall be available at each working location and on materials storing area.
In addition to PPEs, rubber gloves and protective chemical clothes shall be
provided to each personnel physically involved in such activities.
11.7 Contractor/Sub-Contractor shall comply with the requirements for controlling
safety hazards associated with the Concrete work as per Saudi Aramco
Construction Safety Manual.
12. ATTACHMENTS
ATTACHMENT #1
Welding Procedure
ATTACHMENT #2
Job Safety Analysis
ATTACHMENT #3
IFC Drawings / SKETCH PLAN & DETAIL
ATTACHMENT #4
Actual Picture of Damage Anchor Bolt
ATTACHMENT #5
HEMPEL GALVOCOAT 16380
SIKACRETE 114 / SIKA WELL S-2

POLYGUARD 85 ME

A07 Za e 7002586 - Baa - D

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PLANT LOCATION

JAZAN SAUDI ARABIA

NSH DOC NO.

SUBCONTRACTOR CONTRACT NO.

CONTRACT NO. 6600033161

ISSUED FOR APPROVAL

ISSUED FOR APPROVAL

ISSUED FOR APPROVAL

ISSUED FOR REVIEW

NSH DOC NO.

SUBCONTRACTOR CONTRACT NO.

TOOLS & EQUIPMENT AND REQUIRED PERSONNEL

CONSTRUCTION METHODOLOGY AND SEQUENCE

QUALITY CONTROL & QUALITY ASSURANCE

HEALTH, SAFETY & ENVIRONMENT

NSH DOC NO.

SUBCONTRACTOR CONTRACT NO.

SAUDI ARAMCO OIL COMPANY

SNAMPROGETTI SAUDI ARABIA

NASSER S. AL-HAJRI CORP. (NSH)

NSH DOC NO.

SUBCONTRACTOR CONTRACT NO.

Saudi Aramco Construction Safety Manual

Concrete Repair Manual

Protective Coating for Industrial Concrete Structure

Criteria for Design and Construction of Concrete

Base Plate and Anchor Rod Design

Guide to Formwork for Concrete

Formwork for Concrete

Standard Practice for Curing Concrete.

Guide to Sealing Joints in Concrete Structures.

Standard Specification for Carbon Structural Steel

Anchor bolts, Steel, 36, 55 and 105 ksi yield strength

Koppers Super Service Black 30255

MS for Concrete Repair works

MS for Application of Protective Coating on

SUBCONTRACTOR CONTRACT NO.

NSH DOC NO.

Train-3 Foundation Plan Part-3

A07-PR-7301 Single Foundation F & R

Anchor Bolt Details Inch & Metric Sizes

CIVIL SUPERINTENDENT Shall be responsible for monitoring of Repair of

FABRICATION SUPERVISOR & FOREMAN Shall be responsible for the

QC MANAGER Shall be responsible for the assurances of quality

QC INSPECTOR shall be responsible for all necessary inspection to be

NSH DOC NO.

SUBCONTRACTOR CONTRACT NO.

TOOLS & EQUIPMENT:

Power Jack hammer

Hickey or Equivalent Bar Bender

Temperature Monitoring Device

Wooden or Rubber Float

Grinder with Diamond Blade

6. TOOLS & EQUIPMENTS AND REQUIRED PERSONNEL

SUBCONTRACTOR CONTRACT NO.

NSH DOC NO.

A good repair restore the function and

performance of the structure, strength and stiffness, enhances the