EGP3 ONSHORE PROJECT Method Statement for Repairs of Broken Anchor Bolt on Concrete Pedestals DOCUMENT NO. : ONS-HHI-GP-PRO-ST-0012 ABIODUN c | 01-Nov-07 | Issue FOR APPRovaL cw | cue 8 | 27-Oct-07 | issueroramprovat | apiopuN | Kw | CHP A | 25-Sep-07 | issueroRarerovat | apioouN | «ws | CHP rev | Date COMMENT onic [| cu | appr | Company CONTRACTOR APPROVAL: COMPANY APPROVAL: Ci Par Prot Manger REFERENO® ra a DATE: 01-Nov-07 _|pate: 21, Ope, 07 CONTRACTOR Doesment Number: Equipment Tag (irappicable) COMPANY Document Number vrsiet | ovtater | AS! | type [we [S| tet ngneering echnical ons mM ce | pro | st | on | FEGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Conerete Pedestal. _ Revision Log Rev, Date a | 25-Sep-2007 Revised Pages Revision Description \ Issued for Approval 8 | 27-Oct-2007 1,6,10& 11 Issued for Approval [CT Gi-Nov-2007 as67 ‘ssued Tor Approval as Page 2 079EGP3 ~ Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Concrete Pedestal. TABLE OF CONTENTS 10 PURPOSE 20 SCORE 30. DEFINATION AND ABREVIATION 40. REFERENCES DOCUMENTS 50. RESPONSIBILITIES 60 PROCEDURE Page 30f9EGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Concrete Pedestal. 1. PURPOSE This method statement identifies ang illustrates the sequence of operation and methodology trav 9 instalation erection of steel structure ie. while mounting the steet structure columns base plates to ‘would be used for the repairs of broken bolt on concrete pedestal that may accur either du align with the conerete pedestal anchor bolts and properly clasped for fastening into place, manual bolting by application of excessive tightening force andlor due 10 material defects not detected ‘uring manufacturer's factory quality control inspection, and during the civil constuction by the pedestal concrete placement civil team at EGP3 Areas in order to transfer the load applied trom the base plates onto the foundation 2. SCOPE The scope of this method statement is from the identilication of a damaged or broken anchor bolt ‘within @ concrete pedestal to its safe removal, instalation of a new anchor bolt and repair of the Concrete pedestal. It allows for the curing time of the concrete repair and acceptance by the client 3. DEFINITION AND ABBREVIATIONS ONL, Chevron Nigeria timed HH) Hyundai Heavy Industries Limited SUBCONTRACTOR ED-OF Nig. Limited / IOMON EGP 3 ESCRAVOS Gas Project Phase 3 awac Quality Assurance / Quality Contra! HSE Health Safety ard Environment wre inspection and Test Plan Fc Issued for Construction 4. REFERENCE DODUMENTS HHI Procedure ONS-HHI-GP-PRO-CV-0010 Grouting Works (ONS-HHI-GP-PRO-A-0027 Inspection Procedure for Civil Works ONS-HHI-GP-PRO-CV-0018 Method Statement for Conerete Repair Works (ONS-HHI.GP-PRO-QA.0087 Incpection & Test Ptan for erection of steel structures (!7P-S-002) Page 4 0F9EGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Conerete Pedestal. RESPONSIBILITIES HHI shall engure that the assigned Subcontractor implements the HES and quality standards required by the contract, detailed in the appropriate industry codes, clients’ specications, HH! procedures and this method statement during the execution of the work. Any deviation will be brought to the clients’ attention promptly, documented and a consensus reached before continuation of work The Project Manager reports cirecly to the Project Director and has overall esponsialty for the execution of the Project in accordance with the contract and the company Health & Safety Policy, he is responsible for the implementation of Safely, Environment and Quallly procedures on site supported by discipline managers who control site operations and subeontractars. The Steel Structure (Construction) Manager in collaboration with the QA/|QC Manager shall monitor the subcontractor’s compliance with this method statement during execution, HHI QA/QC inspectors. will peform verification, inspection and test activities as defined in ONS-HHI-GP-PRO-QA.0087 Inspection & Test Plan for Erection of Steel Structure (ITP-S-002) and recard all deviations, repairs and modifications The subcontractors’ Project Manager (SCPM) has overall responsibilly for the execution of the: assigned and subcontracted work scope, reporting direcly to the HHI Steel Structural Manager. He 's responsible for the Health, Safety. and Quality Contral of his assigned werk scaze during execution. He is to nominate a QC Inspector to witness the repair activities to completion and produce the final repor, HHI PROJECT MANAGEMENT Project Manager He shall have overall control of the Project, His responsibilities include, but are not limited to the followings: ‘+ Ensures the implementation of the specific Project Quality Plan throughout the duration of tha Project, with the assistance of the Quality Control Manager ‘+ The Project Manager shall ensure that only suitably qualified personnel are assigned to the Project ‘+ Accountable for overall Safely performance of personnel and the implementation and adoption Of the IF principles on the Project. Page 5 OF9EGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Concrete Pedestal. Steel Structure Manager ‘The Stee! Structure Manager shall coordinate the engineering activities related to the execution of the activities within his discipline; he shall be assisted in executing these tasks by discipline engineers. His responsibilies shall include but not be limited to the folowing: ‘+ Checking the compliance of wark executed in actordans ‘and contractual obligations ith the Project quality requirernents ‘© Ensuring interdisciplinary coordination to improve the efficiency and effectiveness of personne! under his control Ensure the availabilty of current documents necessary for the execution of the work. ‘© As:buill mark up of construction issue drawings including any amendments and modifications carried out in the fiels ‘+ He shall be responsible for inputs into scheduling activities, Installation Supervisor The installation supervisor has the responsi lity of directing the subcontractor in the execution of the work ensuring that the repairs are carried out in conformity with drawings and specifications and, completed on schedule, Quality Control inspector The Quality Contiol Inspector shall monitor the application of this method statement and compliance with HHI’s issued procedures by carrying out inspection activities prescribed by the relevant ITP 6. PROCEDURE. 6.1 General ‘© When a concrete pedestal anchor bolt has been identified as being damaged andlor broken and requiring repair, it shall be documented by the HHI QC inspector + The type and extent of damage shall be documented and where necessary photographs taken “The proposed disposition of the concrete pedestal anchor boit will be agreed between HHI ‘Stee! Structural construction team, HHI Engineering and CNL The Proposed disposition shall ‘be documented by the HHI QC inspector and reviewed / approved by CNL prior to final ecceptance. + Prior t9 commencement of the repair works, a barricade shall be put in place to control access. tothe area Page 6 OF9EGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Concrete Pedestal. ‘+ The Concrete Pedestal in which the anchor bott is embedded shall be carefully driled using a onerete Driling Machine, Thereafter, hand tools ( e.g. Chisel and Medium size Hammers} shal be uses to break open the concrete pedestal, wth the driled holes as guide to expose the reinforcement bars. ‘+ Mechanicaland tools shall be made available with all necessary safe guards for the ‘operation, the worker's safety and that af workers in the vicinity wil be considered by conducting a specific risk assessment of the area and any necessary precautions shall be put in place ‘+ Ifthe broken anchor bolt(s) are in a concrete pedestal with an already installed stee! structure stanchion(s}, i shall be removes by dismantling for proper access. + During preparation and grouting repair works of the broken anchor bolts/pedestals, the folowing guidelines shall be adopted in accordance with the Method Statement for Concrete Repair Works (ONS-HHI-GP-PRO.CV-0018) 8). The Concrete Pedestal shall be carefuly marked-out by the Discipline Manager, showing the driting points. Workers shall wear adequate PPE whilst driling, breaking and chipping. the concrete pedestal, the pedestal mat into which the anchor bolt is embedded, brush Cleaning of the broken ichipped surface and the pouring of the Concrete / mortar. bb). The piece of the embedded broken anchor bolt shall be carefully detached from the ‘exposed reinforcement network, and a new anchor bolt shall be carefully set, bonded and propery aligned in place by the Surveyor using necessary precision tools and instruments, «)_ Brushes of good quality shall be available for cleaning the broken/chipped rough surface for the application of the epoxy mortar onto the pedestal to ensure adequate bonding at the interface of the fresh Concrete (C35) with the remaining Concrete Pedestal d)_ The exposed re-enforcoment bars shall be power brushed to ciean metal to remove all traces of rust and concrete residue. If this is insufficient to remove all the dobris, blast cleaning shall be uses. ©), Wood formwork shail be bull, put in place and adequalely braced and supparied, iis to be fiumly secured to prevent any movement during filing/pouring of the Conerete. The Epoxy resin bonding agent is to be properly mixed and applied in accordance with tha ‘manufacturers instructions to ensure that the required adhesion/bonding level is attainment Page 70f9EGP3 - Onshore Project - Method Statement — Repairs of Broken Anchor Bolts on Concrete Pedestal. ) The subcontractors QC Inspector shall check and confirm the survey points and formivork has been carried out as specified before asking HHI QC inspector to verify. This "Hold" point myst be correct before continuing 48). The stipuiated curing time tor she Structural grace Concrete (C35) shall be observed to ‘ensure adequate minimum strength required by he pedestal is attained before foad placement va Erection and Installation of Stee! Structure Columns + On completion of the above processes, the Stee! Structure Stanchions earlier removed shall be re-erected and properly installed by ensuring necessary alignments, plumb setting and bolts snug-tightening checks. Thereatter, the formwork(s) for grouting shall be set in place on the concrote pedestals aboul the Stee! Structure Stanchion’s base plate and grouting works: carried out in accordance with the approved Method Statement for Grouting and Padding (ONS-HHI-GP-PRO-ST-0008). + Grouting process shall ensure the gouge made for access to effect the removal ofthe broken anchor ball piece from the concrete mat on top of which the pedestal is cast is adequately filled with the flowable cementitious grout material and no air is trapzed. The Steel Structure Manager shall ensure that only competent and skiled erectors are used in the erection and bolt tightenizg of steel structural members in order to prevent future occurrence. ‘See the sketch below for the BROKEN ANCHOR BOLT removalirepfacement repairs. Pose 80F9EGP3 - Onshore Project - Method Statement ~ Repairs of Broken Anchor Bolts on Concrete Pedestal. Broken Anchor Bolt Exposed Existing (M32 X 680) to be replaced Re-enforcement Bar of the Pedestal Cracked Broken Anchor Portion of Conorete Pedestal Coated with Epoxy Resin bonding agent Ensures strong, durable bond between the old and the new Concrete CRACKING OF THE CONCRETE PEDESTAL FOR REMEOVAL / REPLACEMENT OF THE BROKEN ANCHOR BOLT / RE-GROUTING Broken Anchor Bolt to be replaced after eracking the concrete pedestal (All Dimension in mm), Page 90f9Page | of | Nigec EGP3 Lead QA Engineer (L9esc1087-smb) From: Mourad, Emad M [Contractor] Sent: Monday, November 12, 2007 11:07 PM To: —_Nigec EGP3 Lead QA Engineer (L9esc1087-smb) Subject: RE: Concrete Pedestal Repair Dave, Looks ok, however | am litie concern about shipping concrete to replace # braken anchor in a small pedestal. | recommend for small pedestal where the volume of removed conerete is relatively large to overall pedestal size, concrete of the entire pedestal to be removed, then 10 be poured monolithically after replacing the bolt In larger pedestal or footing this procedure is ick. Epoxy bondirg agent ( item “e” - section 6.1) should be used in all cases. Regards, Emad From: Nigec EGP3 Lead QA Engineer (L9¢s¢1087-smb) Sent: Fricay, November 02, 2007 7:30 AM To: Mourad, Emad M [Contractor] Ce: Nigec EGP3 Onshore Const MGR (L9esc991) Subject: Concrete Padestal Repair Emad, Please find the attached draft Method Statement, ONS-HHI-GP-PRO-ST-0012 Rec-C, Repair of Concrete Pedestal with Broken Anchor Bolt, HHI have prepared this document here at Escravos site with input and guidance from our EGP3 Team. ‘Would appreciate your review/comment of the dacument before we permit any repair work to commence. Thanks and regards DAVE OUTHWAITE (Alternating with Mike Deere) EGP3 Onshore Lead QA Engineer Chevron Nigeria Limited Escravos, Nigeria ESCRAVOS (Office: +234 1367 6863, GAS PROJECT (Mobile: +234 (0) 8055889108 PHASE 3 +Email L9esct087@chevron.com Radio /D 726039 Call Sign EGP 62 ‘This message may contain confidential information that is legally privileged and is intended only for the use of the parties to whom itis addressed. If you are not an intended recipient, you are hereby notified that any disclosure, copying, distribution or use of any information in this message Is strictly prohibited, If you receive this message in error, please notify me immediately at the e-mailitelephone numbers above. 12/2/2007