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PIPE RACK ERECTION

Using Precast Concrete Elements


and Structural Steel:
Erection of columns
Erected Columns
Erection of Precast Beams
Types of Precast Beams
Continuation: (Precast Beams)
Erection of Precast Beams
Grouting of beam-column
connection:
Grouting with Non-shrink
grout:
Grout Mixing:
Grouted beam-column
connection:
Erection of Structural Steel Module
Steel Columns
Structural Steel Columns:
Continuation:
Erection of one complete structural steel
module:
During Erection:
CHECK FASTENING MATERIALS (12-SAMSS-007 SEC. 4.6)
- HIGH STRENGTH BOLTS, ASTM A325, TYPE 1 , GALVANIZED.
- HEAVY HEX NUTS, ASTM A563 GR DH
- WASHER, ASTM F436

• THE MINIMUM NUMBER OF BOLTS IN A FRAMED CONNECTION SHALL BE TWO


BOLTS (12-SAMSS-007 SEC. 6.2.5.7)

• MINIMUM DIAMETER OF BOLT 20 MM SHALL BE USED IN ALL BOLTED


STRUCTURAL CONNECTION (12-SAMSS-007 SEC. 6.2.5.3)

• ERECTION SHALL BE IN ACCORDANCE WITH THE DRAWINGS AND OTHER


CONTRACT DOCUMENTS

• DURING ASSEMBLY, ALL JOINT SURFACES, INCLUDING THOSE ADJACENT TO


THE BOLT HEADS, NUTS OR WASHERS, SHALL BE FREE OF BURRS, DIRT AND
OTHER FOREIGN MATERIALS THAT WOULD PREVENT SOLID SEATING OF
PARTS (12-SAMSS-008 PAR. IV, MOD. PIP STS05130 SEC. 6.5.8)

• ALL PREASSEMBLIES SHALL BE LIFTED IN A MANNER THAT WILL NOT IMPAIR


THE STRUCTURAL INTEGRITY OF THE MEMBERS. ASSEMBLED STRUCTURAL
MEMBERS SHALL BE LIFTED IN A COMPLETE FRAME.
INSPECTION OF STRUCTURAL ALIGNMENT
DURING ERECTION:

IMPORTANT CHECK POINTS:

„ VERTICAL TOLERANCES FOR STRAIGHT COMPRESSION STRUCTURAL


MEMBERS < 1/1000 OF THE AXIAL LENGTH, (AISC PAR. 6.4.2 & PIP STS05130
PAR. 6.2.1)

„ THE STRUCTURE SHALL BE PLUMBED, LEVELED, AND BRACED BEFORE ANY


FINAL BOLTED OR WELDED CONNECTIONS ARE MADE, PIP STS05130 PAR.
6.3.2.

„ LEVELING PLATES, LEVELING NUTS AND WASHERS, LOOSE BASE PLATES AND
BEARING PLATES ARE SET IN ITS CORRECT ALIGNMENT AND ELEVATION.
VARIATION IN ELEVATION RELATIVE TO THE ESTABLISHED GRADE < +/- 3 MM
(AISC PAR. 7.6 & PIP STS05130 PAR. 6.4.1)

„ ALL COLUMN SPLICES SHALL BE FIELD BOLTED AND CONFORM TO AISC


DETAILING FOR STEEL CONSTRUCTION APPENDIX D (12-SAMSS-007 PAR.
6.2.5.20)

„ REFERENCE
- AISC CODE OF STANDARD PRACTICE FOR STEEL BUILDING AND BRIDGES
- PROCESS INDUSTRY PRACTICES PIP STS05130, ERECTION OF STRUCTURAL
AND MISCELLANEOUS STEEL SPECIFICATION
REPAIR/CORRECTION OF ERRORS OF STRUCTURAL ALIGNMENT
DURING ERECTION

IMPORTANT CHECK POINTS:

„ FIT-UP BOLTS AND DRIFT PINS SHALL NOT BE USED TO BRING IMPROPERLY
FABRICATED MEMBERS AND PARTS INTO PLACE (SPRINGING). (PIP STS05130
PAR. 6.7.1)

„ STANDARD BOLT HOLES SHALL NOT BE ENLARGED BY MORE THAN 1 MM TO


MAKE CONNECTIONS RESULTING FROM MINOR MISFIT (PIP STS05130 PAR.
6.7.2).

„ METHOD OF CORRECTING BOLT HOLE CONNECTIONS THAT MISFIT BY MORE


THAN 1 MM MUST BE APPROVED BY SAUDI ARAMCO.

„ ENLARGEMENT OF HOLES SHALL BE MADE BY REAMING OR DRILLING ONLY


(PIP STS05130 PAR. 6.7.3)

„ THE ERECTOR SHALL MAKE NO MODIFICATIONS OR REPAIRS TO STEEL


JOIST, AND CORRECTION OF FAULTY WORKS SHALL REQUIRE APPROVAL
FROM SAUDI ARAMCO (PIP STS05130 PAR. 6.7.4 & 6.8.2)

„ ONE FILLER PLATE UP TO 1/8 INCH (3 MM) THICKNESS MAY BE USED AS


REQUIRED IN SPACES BETWEEN MEMBERS TO BE BOLTED (PIP STS05130
PAR. 6.7.5)
HIGH STRENGTH BOLTS TIGHTENING INSPECTION &
TESTING:
„ IMPORTANT CHECK POINTS:

„ BOLTS SHALL HAVE FULL THREAD ENGAGEMENT WITH THE NUT.


THE BOLT LENGTH USED SHALL BE SUCH THAT THE END OF THE
BOLT EXTENDS BEYOND OR IS AT LEAST FLUSH WITH THE OUTER
FACE OF THE NUT WHEN PROPERLY INSTALLED (AISC SPECS. FOR
STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 2.3.2)

„ ALL NUTS FOR HIGH STRENGTH BOLTS SHALL BE WAX-DIPPED TO


REDUCE TORQUE DURING INSTALLATION (12-SAMSS-007 PAR.
6.2.5.22).

„ THE ERECTOR SHALL COLOR CODE, DIE PUNCH, OR OTHERWISE


MARK THE ENDS OF TORQUED BOLTS INDICATING THAT THE BOLTS
HAVE BEEN PROPERLY TENSIONED AND ARE READY FOR
INSPECTION (PIP STS05130 PAR. 6.5.7)

„ FAYING SURFACES AND SURFACES ADJACENT TO THE BOLT HEAD


AND NUT FOR SNUG-TIGHTENED OR PRETENSIONED JOINTS SHALL
BE FREE OF DIRT AND OTHER FOREIGN MATERIAL (AISC SPECS. FOR
STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 3.2.1 &
PIP STS05130 PAR. 6.5.1)
THREE TYPES OF BOLTED JOINT:
(MUST BE CLEARLY IDENTIFIED & INDICATED IN THE IFC
OR ERECTION DRAWINGS)

1.) ST – SNUG-TIGHTENED JOINT, A


CONDITION WHERE FAYING
SURFACES IN A BOLTED JOINT
ASSEMBLY ARE IN FIRM CONTACT
AFTER A FEW IMPACTS OF AN IMPACT
WRENCH OR WITH THE FULL EFFORT
OF A WORKER USING A SPUD
WRENCH.
2.) PT – PRETENSIONED JOINT:

A JOINT THAT TRANSMIT SHEAR AND/OR


TENSILE LOAD, WHERE THE BOLT
ASSEMBLY IS FULLY TIGHTENED TO WHICH
THE TENSION IN THE BOLT WILL BE EQUAL
TO A MINIMUM OF 70 PERCENT OF THE
SPECIFIED TENSILE STRENGTH (AS PER
TABLE 8.1 & COMMENTARY – SPECS. FOR
STRUCTURAL JOINTS USING ASTM A325
OR A490 BOLTS).
3.) SC – SLIP CRITICAL JOINT:
SIMILAR TO PRETENSIONED JOINTS BUT THE FAYING
SURFACES HAVE BEEN PREPARED TO PROVIDE A
CALCULABLE RESISTANCE AGAINST SLIP.

ONLY ST & PT JOINT TYPES ARE USED IN THE


STRUCTURAL STEEL PIPE RACKS

PRETENSIONING METHOD ACCEPTED BY SAUDI ARAMCO:


- TURN-OF-NUT PRETENSIONING
- CALIBRATED WRENCH PRETENSIONING
- DIRECT TENSION INDICATOR (DTI) PRETENSIONING

PRIOR TO PRETENSIONING OF BOLTS, THE BOLTED JOINT


ASSEMBLY WAS BROUGHT TO A SNUG TIGHT CONDITION.

WHEN IMPACT WRENCHES ARE USED; IT SHALL BE OF


ADEQUATE CAPACITY WITH SUFFICIENT AIR SUPPLY TO
PERFORM THE REQUIRED TIGHTENING OF EACH BOLT
(12-SAMSS-008 SEC. IV)
TURN-OF THE NUT PRETENSIONING
METHOD:
DTI PRETENSIONING METHOD:
Direct Tension Indicator
„ Specially designed washers,
called direct tension indicators,
or load-indicating devices, have
a series of protrusions that
compress during tightening of
the bolt. When you tighten the
nut fully, the washer
compresses and the protrusions
will flatten, leaving a small gap
under the head or nut. You
verify the amount of tightening
by inserting a thin metal stick
into the gap. This method is the
least preferred by Saudi Aramco
for tightening and verifying the
installation of high-strength
bolts.
CALIBRATED WRENCH PRETENSIONING
METHOD
CALIBRATED WRENCH PRETENSIONING METHOD

TORQUE VALUE CALCULATION (USING AISC TABLE 8.1):


TV = db X Tm X COEFF. FACTOR X1000

SAMPLE CALCULATON FOR 1-1/2” DIA. WHERE; TV = TORQUE VALUE IN FT.-LB.


BOLT db = BOLT DIAMETER IN FT.
Tm = MINIMUM BOLT
TV = 1.5/12 X 103 X 0.21 X1000 = 2700 FT.- TENSION ( Table 8.1)
LBS.
PRETENSION IN KIPS
TO CONVERT TO NEWTON-METER: COEFFICIENT OF FRICTION
(Nut Factor) = 0.21
2700 FT.LBS. / 0.7376 = 3660 N-M 1 KIP = 1000 LBS.
CALIBRATED WRENCH PRETENSIONING METHOD
(AS PER SAUDI ARAMCO REQUIREMENT` - VERIFICATION
OF TORQUE VALUES)

THE TORQUE REQUIRED FOR TIGHTENING SHALL BE


DETERMINED IN THE PRE-INSTALLATION PROCEDURE
VERIFICATION TESTING OF THE FASTENER ASSEMBLY AS PER
(12-SAMSS-008 SEC. I)

A CALIBRATED TENSION CALIBRATOR SHALL BE ONSITE WHEN


TIGHTENING IS TO BE PERFORMED ON PRETENSIONED JOINTS
AND SLIP-CRITICAL JOINTS.

A REPRESENTATIVE SAMPLE OF THREE COMPLETE FASTENER


ASSEMBLIES OF EACH COMBINATION OF DIAMETER, LENGTH,
GRADE AND LOT TO BE USED IN THE WORK SHALL BE CHECKED
AT THE SITE OF INSTALLATION IN A TENSION CALIBRATOR.

„ THE PRETENSION THAT DEVELOPED DURING THE


PRETENSIONING METHOD SHALL BE EQUALTO OR GREATER
THAN 1.05 TIMES THAT SPECIFIED FOR INSTALLATION AND
INSPECTION IN TABLE 8.1
TENSION CALIBRATOR (SKIDMORE)
How The Tension Calibrator Works:
„ Tightening a fastener inserted into
the calibrator creates pressure,
which is transmitted through
hydraulic fluid to a gauge. The gauge
gives a direct reading equivalent to
fastener tension in pounds.

„ Bolt Tension Calibrator Allows You To


Verify:
„ That your fasteners meet minimum bolt
tension specifications.

„ That your impact wrenches are properly


calibrated.

„ That your bolting crew understands how to


achieve proper tension in all types of
fasteners.

„ That you have the right installation tools and


equipment.
HIGH STRENGTH BOLTS TIGHTENING, INSPECTION & TESTING
CALIBRATED

WRENCH PRETENSIONING METHOD

DURING PRETENSIONING OF BOLT ASSEMBLY:

THE TORQUE WRENCH IS CALIBRATED IN IN A DAILY BASIS.

AN ASTM F436 WASHER SHALL BE USED UNDER THE TURNED


ELEMENT.

THE TORQUE DETERMINED IN THE PRE-INSTALLATION


VERIFICATION IS APPLIED TO ALL BOLTS IN THE JOINT,
PROGRESSING SYSTEMATICALLY FROM THE MOST RIGID
PART OF THE JOINT IN A MANNER THAT WILL MINIMIZE
RELAXATION OF PREVIOUSLY PRETENSIONED BOLTS.
CALIBRATED WRENCH PRETENSIONING
METHOD
End of Part II

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