UPGRADE BUILDING FOR RISK MITIGATION AT

Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

Procedure for Structural Bolt Tightening

(Special Process Procedure)

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 UPGRADE BUILDING FOR RISK MITIGATION AT
Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

DOCUMENT APPROVAL
Document Information
Information
Document ID
CRCC-RTR-SP-005
Document Owner M Rehan

Issue Date
11 April, 2023

File Name
Procedure for Structural Bolt Tightening

Amendment History:
Revision Date Amendment History

00 25 March, 2023 1st issue for review and Approval

Document Approvals
Role Name © Signature Date

11 April, 2023
Prepared By QC Supervisor M Irfan Yousuf

Reviewed By QC Manager Mohammad Rehan 11 April, 2023

Approved By Project Manager Osama Al Jaroudi 11 April, 2023

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 UPGRADE BUILDING FOR RISK MITIGATION AT
Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

TABLE OF CONTENTS

1. PURPOSE

2. SCOPE OF WORK

3. REFERENCES

4. RESPONSIBILITIES

5. PRE-INSTALLATION VERIFICATION

6. INSTALLATION PROCEDURE

7. INSPECTION

8. RECORDS

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 UPGRADE BUILDING FOR RISK MITIGATION AT
Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

1. PURPOSE

This procedure is applied for tightening of bolts after the installation of steel column, beam supports and to
ensure that the bolts are installed properly, tightened and inspected as per the applicable code and standards.

2. SCOPE

This procedure covers the methodology and testing of bolt tightening for structural steel work for all buildings
and other miscellaneous structures under the scope of BI-10-02062-0005 “Upgrade building for risk mitigation at
Ras Tanura Refinery”.

3. REFERENCES

A) Project quality plan

B) Schedule Q

C) SATIP-M-001-01 Structural Steel-Pipe rack, Steel Supports & Miscellaneous Steel Structures (Incl.
Piping Supports per Specification)

D) PIP STS05130 Erection of Structural and Miscellaneous Steel Specification

E) 12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel

F) 12-SAMSS-008 Erection of Structural and Miscellaneous Steel

G) SAES-M-001 Structural Design Criteria for Non-Building Structures

H) AISC American Institute of Steel Construction for Structural joint

I) ASTM A325 or ASTMA 490 Specification for Structural Bolts

4. RESPONSIBILITIES

A) Project Manager

The Project Manager shall have overall authority and responsibility for all aspects of the project; He
shall be the responsible for the approval of the project master schedule and control of its fulfilment.

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Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

B) QA Manager

QA Manager shall be responsible for review and ensure all requirements are included.

C) QC Manager

QC Manager shall be responsible for implementation of approved procedures and inspection test
plans as per specifications, codes, standards and guidelines specific to the activity. He shall guide QC
inspectors and ensure inspections & test of the activities as per ITP. Review QC records and ensure
correctness.

D) QC Supervisor

He shall be responsible to ensure that the appropriate approved procedure is followed. He shall
ensure that inspection is executed as per approved ITP and shall assign and monitor QC as per
requirement of schedule Q. He shall ensure that approved material is used.

E) QC Inspector

 Monitor daily activities and verify compliance to approved inspection and test plans.

 Initiates the request for inspection (RFI) after verification of the activities involved are completed

 Prepare daily QC records and final acceptance documentation where required

 Verify and check that all required preparations have been done.

 Prepare, submit and secure approvals of RFI accordingly.

 Co-ordinate with client inspector for the scheduled inspection.

F) Construction Manager

 Ensure compliance by all craftsmen to the content of this procedure, Quality Plan, Inspection and
relevant Customer specifications.

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

G) Mechanical Site Engineer

Shall be responsible for the implementation of this procedure, he shall ensure that the duct to be tested
is ready including all tools & manpower, Coordination with inspector available at site for the scheduled
light test and monitor and supervise the progress of light test.

H) The Construction Team (supervisor/ Foreman) shall be responsible for the following:

 Ensure that all tools & equipment required has been prepared

 Assign manpower qualified to do the job.

 Monitor and supervise the on-going duct light test and sealing works.

 Prior to start of light test, the permit to work from safety- related to scaffolding to use shall be
approved.

I) Safety Officer

 Conduct the toolbox talk to explain the workers about hazards of the activity.

 Inspect tools and equipment used for the activity and ensure that defective tools are removed from
site.

 Ensure that proper barricades are installed to prevent the unauthorized entry and appropriate
signboards posted to alert the workers and visitors.

 Guide the workers during the emergencies such as gas release, injuries, and sandstorms.

 Record the safety observations on Job Safety Log and follow up with construction team for
rectification.

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Document No:
RAS TANURA REFINERY CRCC-RTR-SP-005
B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

5.0 MATERIAL RECEIVING, HANDLING, STORAGE & PRESERVATION:

5.1 Material receiving inspection:

5.1.1 Mill test reports for the structural materials are furnished and verified to conform to the requirements of
the applicable specification. Must be checked that materials are from approved manufacturer.
5.1.2 Mills test reports shall conform to the inspection documentation requirements of EN 10204,
Type 3.1 as follows:

A. Manufacturing declares that the products supplied are in compliance with the requirements of the
order and in which he supplies test results.
B. Test unit & tests to be carried out are defined by product specification, the official regulation &
corresponding rules and order.
C. The document is validated by manufacturer’s authorized inspection representative, independent of the
manufacturing department of the manufacturing department.

5.1.3 Metal products ordered to ASTM or equivalent other specification shall, as a minimum, be marked per
such spec and, in addition, as further specified below.
A. Vendor’s Name or Trade mark.
B. Commercial designation with designator of material type, grade & a designator of physical
conditions, temper and quality.

5.1.4 Markings on metal products shall be legible and sufficient to resist effacement by contact incidental to
normal handling, shipment and storage. Quick drying, waterproof ink, paint, other suitable marking
substances or electrochemical marking may be used. Stamping is permitted on carbon steel products except
ground bars.

5.1.5 when tags are used they shall be made of a durable non-corroding material with markings that
remain legible after prolonged outdoor storage. Stamping is the preferred method for marking on
metal tags.

5.1.6 Marking on metal products shall be placed in a manner which will not affect the usefulness of the
product

5.2 Delivery Inspection:

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

Fabricator is responsible for delivering all materials & documentation to job site in good condition, where
purchaser will be inspected on receiving by Contractor to determine:
A. All items included in Bill of Materials are supplied.
B. All documentation has been received.
C. Check for any damage.
D. Custody & Control receiving, unloading, storage & handling is done in a manner that prevents
distortion, deterioration or damage.
5.2.1 Heavy hexagonal nuts are properly identified and marked with the material grade and
manufacturer's logo in accordance with Attachment 3 of this checklist SAIC-M-2009. (AISC
Specification for Structural Joints Using ASTM A325 or A490 Bolts, Figures C-2.1 & C-2.2)

5.2.2 All bolts, washers and nuts shall be packaged and delivered in rigid, weather proof containers,
cardboard containers are not acceptable.

5.2.3 Mechanically galvanized bolts and nuts shall not be intermixed with hot-dip galvanized nuts and
bolts.

5.2.4 Min test reports for each heat of ASTM A307 bolts are available for review and verified to meet the
requirements of the ASTM A307 specification.

5.2.5 Washer shall be ASTM F436.

5.2.6 ASTM A307 bolt shall be Limited in size to 5/8 inch (16 mm) diameter and smaller.

5.2.7 All bolts, nuts and washers are of new stock.

5.2.8 All ASTM A325 or ASTM A325M high-strength bolts, shall be galvanized. Galvanized washers
and nuts shall be furnished for galvanized bolts.

5.2.9 Mill test reports for each heat of heavy hex bolts are available for review and verified to meet the
requirements of the ASTM A325 or A325M specification.

5.2.10 Mill test reports for each heat of heavy hexagonal nuts are available for review and verified to meet
the requirements of the ASTM A563 specification. (AISC Specification for Structural Joints Using
ASTM A325 or A490 Bolts.

5.2.11 A Shipping List (including total weight), a Bolt List, and a minimum of two sets of final erection

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

and shop drawings shall accompany the first shipment of each release.

5.2.12 All material & documentation were inspected immediately upon receipt & verified that all items
included in Bill of Material have been supplied and all documents have been received. Note: Any
missing items are recorded & reported as per the approved Material Control Procedure.

5.2.13 All pieces shall be clearly marked with a permanent identifying erection mark number.

5.2.14 Any defect observed on the surface of the structural steel after fabrication Shall be reported to
Contractor and be repaired as per approved method of Repair.

5.3 Material Handling, Storage and Preservation:

5.3.1 All materials are free of shipping and handling damages.

5.3.2 Materials shall be kept free of dirt, grease, and other foreign matter.
5.3.3 Lifting of painted structural members shall be done with a non-abrasive choker.
5.3.4 The bottom base plates shall be kept clean and free of any rust or corrosion.
5.3.5 All materials shall be stored and handled in a manner that will prevent distortion, deterioration or
damage or straining. Materials shall be kept free of dirt, grease and other foreign matter. Fastener
component {bolts, nuts & washers) shall be protected from dirt and moisture and kept in closed
containers at the site of installation.
5.3.6 Fastener components(bolts, nuts and washers) shall be protected from dirt and moisture in
closed containers in a protected shelter.
5.3.7 All material are received, unloaded, handled and stored in a manner that prevents
distortion, deterioration or damage to any members.
5.3.8 Contractor shall prepare adequate timber blocks of suitable sizes in the area which shall be used for
storing steel materials upon their arrival and during assembly of the frames.
5.3.9 The requirements in this Section shall apply only as to verify that the fastener assemblies and pre-
tensioned installation procedures performed as required prior to installation.
5.3.10 Inspection tools & tool calibration records for the tools used by the Erector shall be maintained &
available for the examination by Inspector.

6.0 INSTALLATION PROCEDURE:

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

6.1 Field connections for primary structural members, as shown on drawings, shall be bolted with high-
strength bolts conforming to ASTM A325-N, bearing-type connections with threads included in the
shear plane. However, slip-critical-type connections shall be used for connections, subject to vibration
or repeated stress reversal. Slip-critical (friction-type) connections shall also be used for crane girders
and crane girder supports connections. All high-strength bolts shall be furnished with nuts and
washers.
6.2 ASTM A490/A490M Bolts & Galvanized ASTM A325/A325M Bolts shall not be reused per PIP STS05130
requirements.
6.3 Mechanically Galvanized bolts & nuts shall not be intermixed with hot dip Galvanized nuts & bolts per
PIP STS05130 requirements.
6.4 For all primary connection bolts, ASTM A325 bolts shall be used.
6.5 Fastener materials such as bolts, nuts and washers required Material Test Certificate (MTC) to verify
bolting components meet the requirement of specification.
6.6 Fastener components shall be protected from dirt and moisture in closed containers at the site of
installation. Only limited fastener components, which are anticipated to be installed during the work
shift shall be taken from protected storage. Fastener components that are not incorporated into the
work shall be returned to protected storage at the end of the work shift.
6.7 Pre-Installation procedure verification test with tension calibrator will be done for pre-tensioned joint
and slip critical joint as per SATR-M-2002 or SATR-M-2004
6.8 Prior to bolt tightening following requirement to be checked:
6.8.1 After the connections have been assembled, it shall be visually ensured that the plies of
the connected elements have been brought into firm contact and that washers have been
used as per requirement.

6.8.2 Prior to assembly, it shall be visually verified that the faying surfaces of slip- critical joints
meet the requirements as specified in the contract documents.
6.8.3 All bolt holes shall be standard holes as defined in Tables J3.3 and J3.3M of the AISC
Specification for Structural Steel Buildings, unless otherwise specified on the design
drawings.
6.8.4 Before surface preparation, the Fabricator shall remove all sharp corners, burrs (including
bolt hole burrs), weld spatter, slag, weld flux, loose mill scale and other foreign matter.
6.8.5 Hardened washers shall be provided under all bolt heads and/or nuts adjacent to any ply
with oversized or slotted holes. For standard holes, a minimum of one hardened washer
shall be supplied with each bolt.

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

6.9 For joints that are designated for snug-tightened joints, the bolts shall be installed in accordance with
paragraph 6.5.1. For joints that are designated for pre-tensioned or slip critical, the bolts shall be
installed in accordance with paragraph 6.5.2.or 6.5.3.

6.9.1 Snug-Tightened Joints:

All bolt holes shall be aligned to permit insertion of the bolts without undue damage to the threads. Bolts
shall be placed in all holes with washers positioned if required and nuts threaded to complete the
assembly. Compacting the joint to the snug-tight condition shall progress systematically from the most
rigid part of the joint. The snug-tightened condition is the tightness that is attained with a few impacts of
an impact wrench or the full effort of an ironworker using an ordinary spud wrench to bring the
connected plies into firm contact.
6.9.2 Pre-tensioned Joints:
For pre-tensioning methods, paragraph 6.5.2.1 shall be used, except when alternative-design fasteners or
alternative washer-type indicating devices that meet the requirements are used, in which case,
installation instructions provided by the manufacturer and approved by the Engineer of Record shall be
followed.
6.9.2.1 Calibrated Wrench Pre-tensioning:
The pre-installation verification procedures specified in Section 5 shall be performed daily for the
calibration of the installation wrench. Torque values determined from tables or from equations that
claim to relate torque to pretension without verification shall not be used. All bolts shall be installed in
accordance with the requirements in paragraph 6.5.1 with washers positioned as required in drawings.
Subsequently, the installation torque determined in the pre-installation verification of the fastener
assembly shall be 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 pre-tensioned bolts. The part not turned
by the wrench shall be prevented from rotating during this operation. Application of the installation
torque need not produce a relative rotation between the bolt and nut that is greater than the rotation
specified requirement.
6.9.3 Turn-of-Nut Pre-tensioning Method:
Initial tightening of bolts shall be done according to Section 6.5.1 (Snug-Tightened Joints) of this
procedure. When the faying surfaces are in firm contact after a few impacts of an impact wrench or with
the full effort of a worker using a spud wrench (snug-tight condition), the erector shall color code, die
punch or otherwise mark the end of bolts indicating that bolts have been properly tensioned and are
ready for inspection. The nut and protruding end of the bolt are match-marked after snug-tightening is
performed. The part not turned by the wrench shall be prevented from rotating during the turning of nut
or bolt head. After bolt is in snug-tight condition and match-marked, extender shall be inserted on the
spud wrench arm and the nut or bolt head is rotated to the amount of turn specified in Table 8.2. Once
the required Turn-of-Nut procedure completed, Torque wrench will be applied to determine the actual
torque value of the bolt and nut. Torque value will then be used for the actual bolt tightening of all the
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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

bolts installed at site that requires torqueing. This process will be done to each different bolt sizes.
Referring to the commentary on Table 8.2, bolt length exceeds12db. The required turn for such bolts can
be established on a case-by-case basis using a tension calibrator.

7.0 INSPECTION:

When inspection is required in the contract documents, the inspector shall ensure while the work is in
progress that the requirements in the Specification for structural Joints Using ASTM A325 or A490 Bolts, are
met. When inspection is not required in the contract documents, the contractor shall ensure while the work
is in progress that the requirements in the Specification for Structural Joints using ASTM A325 or A490 Bolts
are met. For joints that are designated in the contract documents as snug-tightened joints, the inspection
shall be in accordance with paragraph 7.1. For joints that are designated in the contract documents as
pretension, the inspection shall be in accordance with paragraph 7.2 and 7.4 whichever is applicable. For
joints that are designated in the contract documents as slip-critical, the inspection shall be in accordance
with paragraph 7.3.
Fastener Components shall not be cleaned or modified from the as-delivered condition. Fastener
Components that accumulate rust or dirt shall not be incorporated into the work unless they are re-qualified
as specified in section 7.

7.1 Snug-Tightened Joints

Prior to the start of work, it shall be ensured that all fastener components to be used in the work meet the
requirements. Subsequently, it shall be ensured that all connected plies meet the requirements of
Specification for Structural Joints using ASTM A325 or A490 Bolts. After the connections have been assembled,
it shall be visually ensured that the plies of the connected elements have been brought into firm contact and
that washers have been used as required in Specification for Structural Joints using ASTM A325 or A490 Bolts.
No further evidence of conformity is required for snug-tightened joints. The magnitude of the clamping force
that exists in a snug-tightened joint is not a consideration.

7.2 Pre-tensioned Joints

For pre-tensioned joints, the following inspection shall be performed in addition to that required in
paragraph 7.1
A) When the calibrated Wrench Pre-tensioning method is used for installation, the inspection shall be in
accordance with paragraph 7.2.1

7.2.1 Calibrated Wrench Pre-tensioning: The inspector shall observe the pre-installation
verification testing required in paragraph 6.5.2.1. Subsequently it shall be ensured by
routine observation that the bolting crew properly applies the calibrated wrench to the

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 UPGRADE BUILDING FOR RISK MITIGATION AT
Document No:
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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

turned element. No further evidence of conformity is required. A pretension that is

greater than the value specification in Section 5 shall not be cause for rejection.
7.2.2 A marking system shall be used to mark high strength bolted connection after tightening is
completed. Color Coding: Bolts that are completely pre-tensioned should be marked
“Black” color. Bolts that are not completed shall be marked in “Red” color.
7.3 Slip-Critical Joints

Prior to assembly, it shall be visually verified that the faying of slip critical joints meet the requirements of
Specification for Structural Joints Using ASTM A325 or A490 bolts. Subsequently, the inspection required in
section 7 shall be performed.

7.4 Turn-of-Nut Pre-tensioning Method

Initial inspection shall be done according to Section 7.1. After Snug-tight condition, the nut or bolt head is
rotated to the amount of turn specified in Table 8.2. Final bolt tightening shall be done visually in
compliance with Table 8.2. No further evidence of conformity is required. All equipment’s and
scaffoldings shall have Aramco stickers or safety tags to ensure that they are approved for a safe working
condition.

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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

Minimum Bolt Pretension for Pre-tensioned and Slip-Critical Joints

TABLE 8.1

Specified Minimum Bolt Pretension Tm, kipsa

Nominal Bolt
Diameter db, in. ASTM A325 and F1852 Bolts ASTM A490 Bolts

1/2 12 15

5/8 19 24

3/4 28 35

7/8 39 49

1 51 64

1 1/8 56 80

1 1/4 71 102

1 3/8 85 121

1 1/2 103 148

A equal to 70 percent of the specified minimum tensile strength of bolts as specified in ASTM
Specification for tests of full-size ASTM A325 and A490 bolts with UNC threads loaded in axial
tension rounded to the nearest kip.

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Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

Nut Rotation from Snug-Tight Condition for Turn-of-Nut Pre-tensioning

TABLE 8.2

Bolt Length, in. Disposition of Outer Face of Bolted Parts

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Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

Both faces normal to bolt One face normal to bolt Both faces sloped not more
axis axis, other sloped not more than 1:20 from normal to
than 1:20d bolt axis
Up to and
including 4” X
dia. 1/3 turn 1/2 turn 2/3 turn
Over 4” X dia. Up
to 8 X dia. 1/2 turn 2/3 turn 5/6 turn
Over 8” X dia. Up 2/3 turn
to 12 X dia. 5/6 turn 1 turn
A) Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For required nut
rotations of ½ turn and less, the tolerance is plus or minus 30 degrees; for required nut rotations of 2/3 turn
and more, the tolerance is plus or minus 45 degrees.

B) Applicable only to joints in which all material within the grip is steel.

C) When the bolt length exceeds 12 d b, the required nut rotation shall be determined by actual testing in a
suitable tension calibrator that simulates the conditions of solidly fitting steel.

D) Beveled washer not used.

8.0 RECORDS

SATIP-M-001-01 Structural Steel-Pipe rack, Steel Supports & Miscellaneous Steel Structures
(Incl. Piping Supports per Specification)
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B.I No: 010-02062-0005 Contract No: 6600049822 Rev.00

Date Issued:
Procedure for Structural Bolt Tightening
11 April, 2023

SATR-M-2002 Pre-Installation Procedure Verification Testing Using the Turn-of-Nut Method

(ASTM A325 or ASTM A490 Bolts)

SATR-M-2003 Pre-Installation Procedure Verification Testing of Direct Tensioning Indicator

(ASTM A325 or ASTM A490 Bolts)

SATR-M-2004 Pre-Installation Procedure Verification Testing of Calibration Wrench

(ASTM 325 or ASTM A490 Bolts)

SAIC-M-2021 Receiving Inspection - Bolts, Nuts & Washers for

Structural Connections

SAIC-M-2009 High Strength Bolts Tightening Inspection and Testing

(ASTM A325 or A490 Bolts)

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