2.

11 Anchor Rod Repairs may end up at an angle to the vertical that will not allow the
base plate to be fit over the rods.
Anchor rods may require repair or modification during
Rods can also be damaged in the field by equipment, such
installation or later on in service. OSHA requires that any
as when backfilling foundations or performing snow remov-
modification of anchor rods during construction be reviewed
al. Anchor rod locations should be clearly flagged so that
and approved by the Engineer of Record. On a case-by-case
they are visible to equipment operators working in the area.
basis, the Engineer of Record must evaluate the relative mer-
The anchor rods shown in Figure 2.3 were damaged because
its of a proposed repair as opposed to rejecting the foundation
they were covered with snow and the crane operator could
and requiring the contractor to replace part of the foundation
not see them.
with new anchor rods per the original design.
ASTM F1554 permits both cold and hot bending of an-
Records should be kept of the repair procedure and the re-
chor rods to form hooks; however, bending in the threaded
sults. The Engineer of Record may require special inspection
area can be a problem. It is recommended that only Grade
or testing deemed necessary to verify the repair.
36 rods be bent in the field and the bend limited to 45° or
Most of these repairs are standard simple modifications
less. Rods up to about 1 in. in diameter can be cold bent.
that do not require calculations. The most common anchor
Rods over 1 in. can be heated up to 1,200 ºF to make bend-
rod problems are addressed in the following sections.
ing easier. It is recommended that bending be done using a
rod-bending device called a hickey. After bending, the rods
2.11.1 Anchor Rods in the Wrong Position
should be visually inspected for cracks. If there is concern
For anchor rods in the wrong position, the repair method about the tensile strength of the anchor rod, the rod can be
depends on the nature of the problem and when in the con- load tested.
struction process it is first noted. Is the repair required for
only one rod or for the entire pattern of rods? How far out 2.11.3 Anchor Rod Projection Too Long or Too Short
of position is the rod or pattern, and what are the required
Anchor rod projections that are too short or too long must
strengths of the rods?
be investigated to determine if the correct anchor rods were
If the error is discovered before the column base plate has
installed. If the anchor rod is too short, the anchor rod may
been fabricated, it might be possible to use a different pattern
be projecting below the foundation. If the rod projection is
or even a different base plate. If the rod positions interfere
too long, the embedment may not be adequate to develop the
with the column shaft, it may be necessary to modify the col-
required tensile strength.
umn shaft by cutting and reinforcing sections of the flange
Often, when the anchor rod is short, it may be possible
or web.
to partially engage the nut. A conservative estimate of the
If one or two rods in a pattern are misplaced after the col-
resulting nut strength can be made based on the percentage
umn has been fabricated and shipped, the most common re-
of threads engaged, as long as at least half of the threads in
pair is to slot the base plate and use a plate washer to span
the slot. If the entire pattern is off uniformly, it might be
possible to cut the base plate off and offset the base plate to
accommodate the out of tolerance. It is necessary to check
the base plate design for this eccentricity. When removing
the base plate, it may be required to turn the plate over to
have a clean surface on which to weld the column shaft.
If the anchor rod or rods are more than a couple of inches
out of position, the best solution may be to cut off the exist-
ing rods and install new drilled-in epoxy-type anchor rods.
When using such rods, carefully follow the manufacturer’s
recommendations and provide inspection as required in the
applicable building code. Locate the holes to avoid reinforc-
ing steel in the foundation. If any reinforcing steel is cut, a
check of the effect on foundation strength should be made.

2.11.2 Anchor Rods Bent or Not Vertical

Care should be taken when setting anchor rods to ensure
they are plumb. If the rods are not properly secured in the
template, or if there is reinforcing steel interference, the rods
Figure 2.3. Anchor rods run over by crane.

10 / DESIGN GUIDE 1, 2ND EDITION / BASE PLATE AND ANCHOR ROD DESIGN
 Table 2.4. Hex Coupling Nut Dimensions
Diameter Width Width Height
of Rod, in. Across Flats, in. Across Corners, in. of Nut, in.
w 18 1c 2�
d 1c 1� 2s
1 1� 1w 3
1� 1d 2x 3w
1� 2� 38 4�
1w 2w 3x 5�
2 38 3s 6
2� 3d 4� 7�
Dimensions based on IFI #128 of Industrial Fastener Institute. Material conforms to ASTM A563 Grade A.

the nut are engaged. Welding the nut to the anchor rod is not
a prequalified welded joint and is not recommended.
If the anchor rod is too short and the rods are used only for
column erection, then the most expedient solution may be to
cut or drill another hole in the base plate and install a drilled-
in epoxy-type anchor rod. When the rods are designed for
tension, the repair may require extending the anchor rod by
using a coupling nut or welding on a piece of threaded rod.
Figure 2.4 shows a detail of how a coupling nut can be used
to extend an anchor rod. This fix will require enlarging the
anchor rod hole to accommodate the coupling nut along with
using oversize shims to allow the plate washer and nut to
clear the coupling nut. Table 2.4 lists the dimensions of typi-
cal coupling nuts that can be used to detail the required hole
size and plate fillers. ASTM F1554 Grade 36 anchor rods
and ASTM F1554 Grade 55 with supplement S1 anchor rods
can be extended by welding on a threaded rod. Butt weld-
ing two round rods together requires special detailing that
uses a run out tab in order to make a proper groove weld.
Figure 2.5a shows a recommended detail for butt welding.
The run-out tab can be trimmed off after welding, if neces-
sary, and the rod can even be ground flush if required. For
more information on welding to anchor rods, see AISC
Design Guide 21, Welded Connections, A Primer for Engi-
neers (Miller, 2006).

Figure 2.4. Coupling nut detail for extending anchor rod. Figure 2.5a. Groove weld splice.

DESIGN GUIDE 1, 2ND EDITION / BASE PLATE AND ANCHOR ROD DESIGN / 11