METHOD STATEMENT FOR INSTALLATION OF ANCHOR BOLTS ON EXISTING PIER COPING BEAM FOR GIRDER INSTALLATION

METHOD STATEMENT FOR INSTALLATION OF ANCHOR BOLTS ON EXISTING PIER COPING BEAM FOR GIRDER INSTALLATION

1. PURPOSE

The purpose of this method statement is to outline the procedures for the proper installation of anchor bolts on an existing pier coping beam to ensure secure and accurate girder installation.

2. SCOPE

This method applies to the installation of anchor bolts on an existing pier coping beam, including drilling, setting, securing the anchor bolts, restoring the chipped concrete cover, and installing the steel plate/base plate supplied by the client. An as-built plan of the structure will be provided by the client. All previously approved materials documentation will be provided by the client; therefore, no additional testing will be required.

 

3. RESPONSIBILITIES

• Project Engineer: Ensures that all works comply with project specifications, safety requirements, and approved drawings.
• Site Supervisor: Manages the execution of the works and ensures adherence to the method statement.
• Surveyor: Verifies alignment and positioning of anchor bolts and steel plates.
• Quality Control Engineer: Inspects and ensures compliance with quality requirements.
• Safety Officer: Ensures all safety measures are in place and followed.
• Skilled  and Unskilled Workers: Assist in the execution of tasks, including chipping, drilling, installation, and restoration, under the supervision of the site supervisor.

 

4. MATERIALS AND EQUIPMENT

• Anchor bolts (as per approved design and specifications)
• Drill machine with appropriate drill bits
• Angle Grinder using diamond disc
• Epoxy or chemical anchoring adhesive
• Measuring tape, chalk line, and template
• PPE (helmets, gloves, safety goggles, etc.)
• Chipping tools (jackhammer, hammer, and chisel)
• Temporary access platform (scaffolding or ladder)
• Concrete repair mortar (non-shrink grout)
• Bonding agent
• Trowel and finishing tools
• Steel plate/base plate (supplied by client)
• Welding machine (if required)

 

5. PROCEDURE

 

5.1 Preparation

 

1. Install access (such as scaffolding or ladder) prior to conducting inspection to ensure safe and convenient evaluation of the existing structure.
2. Review project drawings and specifications to confirm the type, size, and location of anchor bolts.
3. Conduct site inspection to ensure the existing pier coping beam is free of defects that may affect installation.
4. Mark the positions of the anchor bolts using templates or chalk lines.

 

5.2 Chipping to Expose Rebars

1. Cut the area of concrete to be chipped off using grinder prior to chipping at the marked positions to expose the reinforcement bars.
2. Use a jackhammer or hand tools carefully to avoid damaging the existing reinforcement.
3. Ensure that no rebars are cut or damaged, as cutting rebars is not allowed in this scope.
4. After exposure, clean the area and prepare it for inspection.
5. Provide safe access for inspection before proceeding to drilling activities.
6. Once the inspection is completed and approved, proceed to the next step.

 

5.3 Drilling and Cleaning

1. Drill holes at the marked positions using a rotary hammer drill, ensuring the required depth and diameter as per design specifications.
2. Clean the holes thoroughly using compressed air to remove dust and debris.
3. Use a wire brush to remove loose particles inside the hole.

 

5.4 Installation of Anchor Bolts

1. Prepare the epoxy/chemical anchor adhesive as per the manufacturer’s instructions.
2. Apply the adhesive into the drilled hole using a dispensing tool.
3. Insert the anchor bolt into the hole by slowly rotating it to ensure even distribution of the adhesive.
4. Allow the adhesive to cure as per the manufacturer’s recommended curing time before applying any load.

 

5.5 Restoration of Chipped Concrete Cover

1. Clean the chipped area to remove dust, loose particles, and contaminants.
2. Apply a bonding agent to the exposed surface to ensure good adhesion of the repair mortar.
3. Prepare the concrete repair mortar (non-shrink grout or polymer-modified mortar) as per the manufacturer’s instructions.
4. Fill the chipped area with the prepared mortar, ensuring proper compaction and coverage.
5. Use a trowel to level and finish the surface to match the original concrete profile.
6. Allow the repair material to cure as per the manufacturer’s recommended time before applying any load.
7. Conduct final inspection to ensure the restored surface meets project specifications. 

5.6 Installation of Steel Plate/Base Plate

1. Verify the dimensions and specifications of the steel plate/base plate as per approved drawings and client instructions.
2. Position the steel plate/base plate over the installed anchor bolts, ensuring proper alignment.
3. Use leveling shims to achieve the required elevation and alignment.
4. Secure the steel plate/base plate using nuts and washers, tightening them to the specified torque.
5. If required, apply grout underneath the steel plate to ensure full contact with the concrete surface and allow proper load transfer.
6. Allow the grout to cure as per the manufacturer’s recommendations before proceeding with girder installation.
7. Conduct a final inspection to confirm that the steel plate/base plate is properly installed and meets the required specifications.

 

5.7 Inspection and Testing

1. Check alignment, depth, and levelness of installed anchor bolts.
2. Inspect the restored concrete surface for proper adhesion and finish.
3. Inspect the installed steel plate/base plate for alignment, elevation, and secure fastening.
4. Any discrepancies should be rectified immediately before proceeding with girder installation.

 

5.8 Removal of Access

1. Inspect the temporary access platform (scaffolding or ladder) to ensure it is stable and safe for removal.
2. Dismantle scaffolding or ladders in a controlled manner, following safety protocols.
3. Remove all temporary supports and materials used for access.
4. Conduct a final inspection to ensure no debris or obstructions remain in the work area.
5. Dispose of any waste materials in accordance with environmental and safety regulations.

 

6. SAFETY AND ENVIRONMENTAL REQUIREMENTS

1. Ensure all personnel wear appropriate PPE at all times.
2. Provide barricades and warning signs around the work area.
3. Follow proper handling and disposal of chemical adhesives, repair materials, and grout.
4. Maintain good housekeeping at the worksite to prevent hazards.

 

7. ACCEPTANCE CRITERIA

• Anchor bolts must be installed as per the approved design and specifications.
• Ensure proper alignment and positioning for girder installation.
• Restored concrete cover must be uniform and bonded properly with no cracks or voids.
• Steel plate/base plate must be properly aligned, secured, and grouted as required.

 

8.       ATTACHMENTS

(Previously approved materials documentation (provided by the client))

• Material specifications
• Manufacturer’s instructions for epoxy adhesive, concrete repair materials, and grout
• As-built plan of the structure (provided by the client)