Date : March 14, 2013

No. Rev. : 0
WORKING METHOD Page No. : 2 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

APPROVAL
NAME POSITION SIGNATURE DATE
Coordinator

Checked

Approved

REV DATE REVISION DESCRIPTION BY CHK APPD

Rev 00
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 3 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

CONTENT
I. SCOPE
II. APLICABLE DOCUMENT
III. CHIPPING OF FOUNDATION SURFACE.
IV. INSTALLATION OF PAD LINER
V. GROUT OF ANCHOR BOLT
VI. ALLIGNMENT AND LEVELNESS OF EQUIPMENT
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 4 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

I. SCOPE

This technical specification cover for chiping foundations , install pad liners, grouting of anchor bolt and
levelness & alignment for the equipment for the Bluescope project.

II. APLICABLE DOCUMENT

a) Engineering Drawing.
b) Inspection Report

III. CHIPPING OF FOUNDATION SURFACE

3.1 Chipping of foundation plane.

a. Remove the laitance layer of foundation concrete until blast appears.

b. Cover the anchor hole with plates so no chipping matters enter.
c. Chipping dept from foundation top is more than 20 mm, and chipping width of foundation
concrete is 100 – 140 mm.
d. After chipping clean and remove the dust and rubbish.

3.2 Cleaning and wetting foundation surface.

a. Clean the concrete surface for pad and remove the dust and rubbish, free standing water on
foundation and bolt holes, steel shall be free from dirt, grease, etc.
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 5 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

b. Water the concrete surface before mounting pad to keep it wet. Use cloth to remove
excessive moisture on the pad right before mounting the pad.
c. Soaking concrete surface with clean water for 24 hours before grouting (minimum 4 hours).

3.3 Preparation of mould.

IV. INSTALLATION OF PAD LINER

4.1 Mounting PAD Liner on Foundation Procedure.

a. Place the dry mortar in the correct position (based on approved drawing).
b. Set the padding plate on top of the dry mix mortar grout, automatic level to set the pad plate
to the correct elevation.
c. After the pad has set, re-check the padding plates as to levelness and elevation by auto level
and others.
d. After mortar grout is dry check the bonding between pad plate and mortar by the place
(knock) with small hammer.
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 6 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

4.2 Arrangement of PAD liner on Foundation

Provide pad on both side of the anchor bolt for equipment as shown bellow.

a.After foundation inspection for installing and centering, measure the dimension from the
centerline with a tape measure to ink the exterior circumference of the equipment.
b.In principle, mount installation seat where concentrated load is expected as well.
c. Provide installation seat where concentrated load is expected as well.
d. When the base frame is deflected at installation, provide installation seats.
e. A : Base liner length x ½ .
B : Interval between anchor hole to end of base liner to be less than 70 mm.
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 7 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

4.3 Preparation of Mortar

a. Mixing ratio ( weight ratio ) for mortar compound shall be as per following table

Non shrinking
Cement River sand water / cement
mixed material

Weight
ratio 1 1 1 0.35 - 0.4

per 1 m3 750 kg 750 kg 750 kg 260 - 300 kg

b. To use purified water for marking the mortar compound.

c. Avoid warm water higher than 300 C from coming contact with the material. The
temperature of water to be used shall be between 100 C until 300 C.
d. Use de-salts river sand. In case of sea sand, thoroughly wash it before use.
e. Put in the order of sand, cement, and non shrinking mixed material. Mix them thoroughly
before adding water.
f. One batch shall not exceed the volume that can be placed within 15 minutes.
g. Do not use mortar becoming firm. Never use remixing mortar by adding some water.
4.4 Pad Mounting

a. Pour mortar little and settle it well with a hammer or a bar. Do not settle too much mortar
more than 20 mm at once.
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 8 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

b. There shall no be rust on the surface of base liner. If any, remove the rust with grinder be
use.
c. After setting the mortar, put a base liner into mortar by lightly hitting it with a wooden
hammer.
d. When the hight is too low, do not add mortar on to it. Dig out and remove the mortar to
regain the original condition. Then, place mortar all over again.

4.5 Pad Precision Height and Levelness

The precision of height and levelness of pad shall be as follow :

Precision Tool to be used

Set height at Spot at Corner +0 Y - Level

to Corner -1mm Steel rule

Levelness (Each direction) 0.1 mm/m level

4.6 Curing Procedure.

The curing time depend on the moisture ratio, however, conform to the following curing time,

time

Important equipment 72 hr

General equipment 48 hr

0
a. The optimum temperature of curing is around 20 C. Therefore, provide heat insulation
when it is too cold, and cover it with a wet linen when it is too hot.
b. Pay attention to avoid foreign matters dropping on the pad while curing.
c. Protect the pad liner from vibration, impact and load while curing.
4.7 Inspection.
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 9 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

a.Check for the abrasion between base liner and mortar, and between mortar and concrete.
b.In case pad liner unaccepted, never give local repair or correction. Always place it all over
again.
c. Set height and levelness.
d.Pad position and quantity.
V. GROUT OF CHEMICAL BOLT.
5.1 Grout the chemical bolt’s hole.

After centering the anchor bolt, fix the anchor bolt as shown below,

a. Preparation.
1. Inside Surface concrete of chemical bolt hole shall be chipping first. At about 20 mm in
depth, then cleaning with air pressure shall be done.
2. Remove foreign matters, water, and cement chips and clean the chemical bolt hole prior
to grout anchor.
3. Make sure that the chemical bolt shaft center and equipment hole center is aligned
better.
b. Preparation of Mortar.
1. Use grouting material as per manufacture technical requirement.
2. Water to be used for mixing grouting material shall be fresh and clean and the
temperature of water not less than 25 0 C (apply ice to control the temperature).
3. Formulation of mixing must be as following,
 Every 25 kg of grouting material (non shrink grout) should be mixed with 3,8 liters of
water.
 Never used sand for mixing.
 Mixing time shall be 3 – 5 minutes long
 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 10 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

 The temperature of mixing not more than 30 0 C (use temperature detector).

 Taking compressive strength of grout samples for 3,7 and 28 days.
c. Pouring.
1. Once started pouring continuously pour without stopping until finishes refilling
completely.
2. During pouring and curing, avoid vibration.
3. When mortar is hard to pour in the gravity force, insert a bar from the circumference
side to push a little to help mortar pouring.
4. Avoid vibration to the mortar by a vibrator.
5. Do not push and pat mortar for a long time.
6. The pouring level shall be 20 – 50 mm lower from the foundation concrete.
7. After pouring, completely removed excessive mortar around the pouring port.
5.2 Curing.

The curing time depends on the moisture ratio, however, conform to the following curing time,

Time

General equipment 7 days

0
a. The optimum temperature of curing is around 20 C. Therefore, provide heat insulation
when it is cold, and cover it with wet linen when it is too hot. Keep wet as per manufacturer
requirement to protect it.
b. Protect the pad liner from vibration, impact and load while curing.

VI. ALLIGMENT AND LEVELNESS OF EQUIPMENT

 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 11 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

Setting of Equipment Height

a.With auxiliary bench mark for installation as a reference, use Y- level for the height setting.
b.Position the height and adjust it with liners and shim.
c. Securely tighten the anchor bolts.
d.Do not adjust the height by tightening or loosing the anchor bolts.
e.Installation precision shall be within the specified tolerance.

Setting Alignment of Equipment

a. Mark on foundation to setting nozzle orientation.
b. With installation center mark as reference, use plumb bob than piano wire.
c. Align the equipment right angled center to the installation reference right angled center.
d. Installation precision shall be within the specified tolerance.

Setting of Right Angled Center for Equipment

a. With installation right angled center mark as a reference, use plumb bob than piano wire.
b. Align the equipment right angled center to the installation reference right angled center.
c. Installation precision shall be within the specified tolerance.

Levelness of Equipment
a. Use precision level and straight edge
b. Adjust the levelness with a tapper line
c. Securely tighten the anchor bolts. Do not adjust the level by tightening or loosening the
anchor bolt.
d. For installation precision, refer to the installation manual.

Install shim plate.

 Date : March 14, 2013
No. Rev. : 0
WORKING METHOD Page No. : 12 of 12
INSTALLATION EQUIPMENT By Chk Appr
Esu Nwa Rph

When tapper liner is not enough to make necessary adjustment, insert shim plates on the base
liner.Try to use minimum number of shim plates.