Document No. | MS_ MECHANICAL JOINT(3) Rev. 0 ire a eae WASKITA METHOD STATEMENT OF MECHANICAL JOINT INSTALLATION USING FUJIBOLT TYPE-R and TYPE-R II. Points and Rules Attachment Table of Contents Work Description . Location to be Applied (Column Starter Bars) 2.1, Location to be Applied .. 2.2. Criteria Application of Mechanical Joints (Fujibolt and Splice Sleeve). 2.3. _ Distinction of Type R and R II BARN . Dimensions of FD Grip Joint R and RII Type. 3.1, _FD Grip Joint R, 3.1.1. Dimension of Hexagonal Sleeve.. 3.1.2. Product Dimension (After Clamping) .. 3.2. FD Grip Joint RI.. 3.2.1. Dimension of Round Sleeve. 3.2.2, Product Dimension (After Clamping) .. Baoan |. Standard Operation Procedure 4.1. Material Preparation 4,2. Marking on Rebar 4,3. Setting Sleeve... Checking Sleeve Insertion into Rebar. Checking Marks. Special Care for FD Grip Joint R. 4.4 Clamping... 45 Reporting and Inspection 4.5.1 Inspection of Sleeve Diameter after Clamping. 4.5.2 Inspection of Marking Position after Clamping 4.5.3 Inspection of Existence of Non-Clamped Sections after Clamping 4.5.4 Recording of Inspection Sheet 5.1, Points and Rules Prior to the Wo! 5.2, Points and Rules Prior to Clamping .. 5.3. Points and Rules Prior After Clamping . Hydraulic Pump and Clamping Tool Instruction, 45 6.1, Specification of Hydraulic Pump for FD Grip Joint R and RII Type: 5 6.2. Specification of Clamping Tool for FD Grip Joint R and RII Types. 16 6.3. Shape of Clamping Die. 6.4. Use Metho 6.5. Precaution 7.1 Inspection Sheet .. 7.2 Qualification Certificat 20 7.3. Material Brochure1, Work Description ‘This method statement describes the detailed procedure for splicing column main rebar using two (2) types of mechanical joints which are FD Grip Joint R Type (Hexagonal Sleeve) and FD Grip Joint R II Type (Round Sleeve). These mechanical joints are inserted into a specified length of rebar and are clamped using the hydraulic clamping machine. Due to the clamping process, the sleeve and rebar adhere, and the tensile force and compression force are conveyed by the shearing force of the rebar ridges and abrasion between the sleeve and the rebar. Mechanical joints for 029, D25 and D22 shall be FD Grip Joint R Type, while mechanical joints for D32 shall be FD Grip Joint R II Type in accordance with the material approval. 2. Location to be Applied (Column Starter Bars) 2.1. Location to be Applied2.2, Criteria Application of Mechanical Joints (Fujibolt and Splice Sleeve) Technically, mechanical coupler provided by Fuji Bolt or Splice Sleeve shows no relative merit, because both couplers satisfy the criteria of Class SA specified by JSCE. Manufacturing places are a major difference between two suppliers. While Fuji Bolt is manufacturing the couplers in Indonesia, Splice Sleeve Is manufacturing them in Japan. We, as a contractor, would like to avoid the delay of delivery regarding importing process. Therefore, the Contractor is going to apply Fuji bolt rather than Splice Sleeve as many as we can for this project. However, the mechanical coupler of Fuji Bolt requires a special clumping machine when re-bars are coupled, and the clumping machine requires more space than grouting tools, which are used for the couplers of splice sleeve. It is concluded that the couplers of Fuji Bolt are applied where enough space is secured for the clumping machine, and the couplers of Splice Sleeve are applied where enough space is not secured for the clumping machine. Criteria Application: Space between re-bars Fuji Bolt Splice Sleeve D22_| Pitch: More than or equal to 125 __| Pitch: Less than 125 mm, and more mm. than or equal to 44 mm. Row: More than or equal to 150 mm. | Row: Less than 150 mm, and more than or equal to 4 mm. D25_| Pitch: More than or equal to 125 _| Pitch: Less than 125 mm, and more mm. than or equal to 48 mm. Row: More than or equal to 150 mm. | Row: Less than 150 mm, and more than or equal to 48 mm. D29__| Pitch: More than or equal to 125 _| Pitch: Less than 125 mm, and more mm. than or equal to 54 mm. Row: More than or equal to 150 mm. | Row: Less than 150 mm, and more than or equal to 54 mm. D32_| Pitch: More than or equal to 125 | Pitch: Less than 125 mm, and more mm. than or equal to 59 mm. Row: More than or equal to 150 mm. | Row: Less than 150mm, and more than or equal to 59 mm. eee oe hetar eee ee suetace of concrete 2.3. Distinction of Type R and R II There is no criteria to distinguish Type R and Type R II. The following is the reason the two types of couplers are applied. Currently, only type R is available for D22, 25 and D29. Meanwhile, only Type R II is available for D32.3. Dimensions of FD Grip Joint R and RII Type 3.1 FD Grip Joint R 3.1.1 Dimension of Hexagonal Sleeve Standard hexagonal sleeve dimensions are referred to Fig-4.1.1 = (Crass Section Surface Fig-3.1.1 FD Grip Joint R Type Sleeve Dimension Diameter 1; (mm) Bi(mm) _ | D: (mm) | p22 100.0 36.0 25.8 D5 110.0 41.0 29.0 (29 125.0 48.0 324 Allowable Tolerance [#1.0 405 22.0% | 3.1.2 Product Dimension (After Clamping) ‘Standard dimension of the joint clamped using the hexagonal sleeve is shown in Fig- 3.1.2. Stefi FAA Fig-3.1.2 FD Grip Joint R Type Product Dimension Diameter b (mm) D2 (mm) D22 110.0 MS p25 LL 38.5 029 B70 45.0 Allowable Tolerance | -10%, +15% | -6%, +2%3.2 FD Grip Joint RIT 3.2.1 Dimension of Round Sleeve The sleeve dimension of the FD grip joint RII type is indicated in Figure 3.2.1. Fig. 3.2.1 FD Grip Joint RII Type Sleeve Dimension Size T(mm) d(mm) i 032 146.0 56.5 Allowable Tolerance #20 +0.5, -2.0 3.2.2 Product Dimension (After Clamping) ‘The dimensions of the sieeve for clamping of the FD grip joint R II type are indicated in Figure 3. Fig. 3.2.2 FD Grip Joint RII Type Product Dimension Size t D 32 i574 48.4 Allowable -10%, +25% | +29, -5% Tolerance4, Standard Operation Procedure Flowchart of FD Grip Joint R and RII Type Work is shown below. Material preparation (Sleeves and Rebar) y Preparation of equipment to be used (Hydraulic pump, Clamping Machine, and Jig tools) 44 4.2 q Marking on rebar q Setting sleeve Y Clamping y Reporting and inspection Material Preparation 1) Rebar + Ensure that all rebar is available and in good condition * Check the rebar diameter, length and steel grade (roll mark) that will be connected to the mechanical joints. + Remove unwanted rust, debris and dust by using a wire brush. * Electric grinder with grinding disc shall be used when cutting the rebar. 2) Sleeve * Ensure that all sleeves are available and in good condition. * Check Mill Sheet and Shipment Inspection Sheet. * Hexagonal sleeve will be properly stored to the designated storage area to avoid contamination from dust and water. Remove unsolicited materials that may affect the physical condition of the hexagonal sleeve. Marking on Rebar 1) Marking color and position Marking of rebar shall be carried out before setting up the sleeve. Use paint or any material that can be used for marking and will not be easily worn away. a, When marking a rebar, use the marking gauge as shown in Figure 4.2.Fig-4.2 Marking Gauge b. The marking distance and shape shall be as indicated in the following figure. ‘The marking length shall be 20 mm, Distance (L) from Rebar End eee [20 or wider Table 4.22 Marking Distance of FD Grio Joint R [ Marking Distance p22 | 2s | 029 [ Distance (L) from rebar end(mm) | 50 | 55 | 62 Fig. 4.26 Marking Distance of FD Grip Joint RIT Marking Distance p32 Distance (L) from rebar end (mm) | 6043 43.1 43.2 433 Setting Sleeve Checking Sleeve Insertion into Rebar Check the insertion status of all sleeves into rebar. Insert the sleeve into connecting rebar and confirm that the insertion length can be more than 1/2 of the sleeve length. IF insertion is difficult due to a burr, bending, etc., correct the corresponding section using a grinder, etc. When the rib height is too high and rebar cannot be inserted, also correct with a grinder. Checking Marks Check marks on all connecting rebar. Before starting to clamp, visually check that the marks are on the connecting rebar. For those without a mark or when the mark is unclear or which have disappeared, execute marking again, 1) Insert the sleeve into a rebar and set the position by aligning with the marking. EEE 2) Set the hexagonal sleeve on one rebar in advance. == 3) Move the hexagonal sleeve to the marking position. — Special Care for FD Grip Joint R 1) After checking functionality of hydraulic clamping machine, the hexagonal sleeve will be set by the hydraulic camping machine. The orientation of the hexagonal sleeve shall be checked as shown in the illustration below. The hexagonal sleeve shall be put within the marks on the rebar, The orientation of the vertical rib on the rebar does not matter.Hexagonal se x +O++O+ Fig-4.3.3 Correct Orientation of Hexagonal Sleeve 2) The shape of the hexagonal sleeve will become round after clamping. This, indicates that the clamping has been done properly. (1) Correct direction K AL. Ly Ny When only two edges of hexagonal sleeve are in one side of die, the hexagonal sleeve turns around like illustration above, and the shape of the hexagonal sleeve will not become round after clamping. In that case, the portion shall be re-clamped to make round. Sleeves clamped with incorrect direction can be easily distinguished by checking with D2 gauges. 1044 Clamping 1) Hydraulic Clamping Machine Clamp FD grip joint R and RII type using a hydraulic unit. Attach the die that matches the connecting rebar diameter and a clamping machine. Correctly connect the power supply, hydraulic pump, hydraulic hose, and clamping machine and check the performance. If the construction equipment Is not working property, investigate the cause of the abnormality and take appropriate measures for the normal performance, The details are provided in the “6. Hydraulic Pump and Clamping Tool”. 2) Clamping Clamping will be executed at the construction site by using balancer to support the weight of clamping machine. See the figure 4.4a. Firstly, set both ends of the sleeve on the marks of rebar. After confirming the correct sleeve position, operate the hydraulic machine. Then, execute clamping on the entire length of the sleeve. Clamp one side and the other side in order. ‘After clamping, confirm that both ends of the sleeve are on the markings. When any sections are left unciamped, re-clamp those sections again. It shall not leave any unclamped section (it shall confirm more than 95% is clamped). Fig-4.4a Balancer to Support Clamping Machine Fig-4.4b Difference of before and after Clamping (Hexagonal Sleeve) Fy4,5 Reporting and Inspection 4.5.1 Inspection of Sleeve Diameter after Clamping ‘After clamping, check the sleeve diameter by using D2 gauge. The clamped sleeve shall be inserted through portion of the gauge but shall not be inserted its stop portion. If unaccepted, execute the proper process such as re-clamping. aa \Deaeue Fig-4.5.1 D2 Gauge 4.5.2 Inspection of Marking Position after Clamping After clamping, visually check that both ends of the sleeve are on the markings. Check that the sleeve ends are positioned over the markings for all clamped sleeves. For a defective sleeve, take an appropriate measure such as cutting the sleeve with a grinder and re-clamping, etc. Fig-4,5.2 Sleeve on Marks 124.5.3. Inspection of Existence of Non-Clamped Sections after Clamping After clamping, visually check that there is no unclamped section on the sleeve. Check all clamped products for the existence of unclamped sections, For a defective sleeve, take an appropriate measure such as re-clamping. 45.4 Recording of Inspection Sheets The Contractor shall record the results of 4.5.1, 4.5.2 and 4.5.3 in the "FD Grip R type Work Inspection Report” and/or “FD Grip RII type Work Inspection Report” in the attachment 7.1 for three (3) clamped sleeves at the start of operation and four (4) random clamped sleeves on the same day of each diameter of sleeve every operation day. If any correction is executed, record the correction method and correction location, 5 Points and Rules 5.1__ Points and Rules Prior to the Work In Case No.) Tem ‘Check Item Timing Quality Controt of Faire T_| Receiving | Rebar diameter, | Upon Check itis Replacement of the | rebar grade, and receiving within the rebar \ quantity specification. 2 | Receiving | Sleeve diameter, | Upon Check ift Replacement of the sleeves grade, receiving within the sleeve and quantity specification. 3 | Checking | Qualification Before ‘Check if the ‘Assignment of the Technician | Certificate (Refer | starting the | qualification is _| qualified person of jointing | to Attachment | construction | appropriate. qualification _| 7.2) 5.2 Points and Rules Prior to Clamping Tn Case No. | Item ‘Check Item Timing Quality Contro! ee ranivs i | Checking | Rebar Every Check the rebar diameter, | Replacement of the rebar diameter, construction | grade, and quantty based rebar grade, day on the specification and and quantity approved shop drawings. [2° | Checking Sleeve Every, Check the sleeve diameter, | Replacement of the | | sleeve diameter, construction | grace, and quantity based | sleeve grade, day on the Engineer's material and quantity approval. 3 | Checking | Performance | Every Check if the operation is | Report to the hydraulic construction | normal ‘Supplier for Unit day appropriate action 4 | Checking | Existence of | Before Check if all markings on the | If there is any marking marking stamp | clamping | rebar are in the correct | rebar without a stamp positions, marking, mark the rebar. 5 | Condition | Cutting burr | Every Check ifthe Correct using @ of rebar and bending of | construction | steve can be inserted into | grinder, etc. end rebarend | day all rebars. 2B5.3 Points and Rules After Clamping In Case No. Item Check Item Timing Quality Control rpaine 1 Checking Visually check | Every clamping | Check if both | Cut the rebar with marking the sleeve ends ends of the sleeve and and markings sleeve areon | re-clamp, | after clamping the markings. 2 | Checking ‘Check the Three (3) times at | Check the Re-damp clamping clamping the start of clamping diameter diameter using | operation and _| section passes the D2 gauge, | four (4) times _ the D2 gauge later 3 | Clamping Fillin Inspection | At the end Check any ‘Appropriate actions inspection Report of clamping comments to the comments. record ‘on the arisen on the construction day | Inspection Report 146. 6.1 Hydraulic Pump and Clamping Tool Instruction Specification of Hydraulic Pump for FD Grip Joint R and RII Type tem Specification Model name HK44/1 Capacity 2.2 kW Voltage S-phase, 200V Discharge High pressure 1.57 I/min amount Low pressure 6.7 min Set High pressure 68 MPa pressure Low pressure 10 MPa Hydraulic oil 1SO VG32 (or equivalent) Oil tank capacity 6.91 Power supply cord 3m | Remote controller cord 3m = Weight 40 kg Safety valve Prossure teh Fig. 6.1 Hydraulic Pump 15,6.2 Specification of Clamping Tool for FD Grip Joint R and RII Type 1) 75 kg Clamping Too! [Item | Specification Objective rebar D25, 29, D32 dimension ‘Actuation system Nominal output 100 tons (980 kN) 2) 45 kg Clamping Too! Double-acting system | Using hydraulic 68 MPa pressure | [Weight 759 Nominal output | 100 tons (980 kN) Using hydraulic 68 MPa m Specification ] Objective rebar D22, 025, D29 dimension Actuation system | Double-acting system Fig. 6.2 Clamping Machine 6.3 Shape of Clamping Die 1) FD Grip Joint R Type 22 | b25 | D29 R (mm) 18.3 | 21.0 | 24.5 H (mm) 16.5 | 18.5 | 22.0 162) FD Grip Joint RII Type 32 H (mm) 20 R(mm) | 24.00 Fig. 6.3 Clamping Die Use Method 1) Insert the male coupler of the hydraulic pump into the female coupler of the tool. Tighten the coupler securely. 2) Select a die that fits the clamping rebar size. 3) 4) Connect the power supply cord plug to the DC200V outlet. 5) Press the “Pull” button (for descending) on the remote controller. The piston descends to the lowermost position. 6) Press the “Push” button (for ascending). The motor starts rotating and the oil pressure is applied to the cylinder, 7) When stopping the cylinder in the middle position, release your finger from the “Push” button. The motor rotation stops, and transmission of oil also stops. If the pressure is applied, the applied pressure remains. wv8) 9) While continuing to press the “Press” button, the pressure increases. When the pressure reaches the set pressure (700 kg/cm2), the motor stops, and the set pressure remains. When the “Pull” button is pressed, the solenoid works, and the pressure is released. The oil of the cylinder returns to the tank inside (the piston descends). 10) Remove the releasing pin of the tool and open the yoke. Remove the clamped sleeve. 11) After finishing use, put the cap on the coupler in order to prevent attachment of foreign material and flaws. 6.5. Precaution for Use 3) 2) 3) 4) 5) 6) Use clamping sleeve and die in correct combination. [Gonbete connection [ssomplote connedtion No dearano [tate counter Art x [Countering [Femais napier Do not operate the “Pull” button for 30 sec. or longer continuously. Otherwise, the solenoid overheats, and returning operation becomes impossible. When interrupting the operation, after finishing the operation, and when moving the pump, ensure to unplug the power supply. Do not execute empty clamping. During the operation, do not allow the head section to face any person or yourself. During the operation, do not touch the die section and moving section. 18Ts aa Attachment Inspection Sheet FD Grip R-Type Work Inspection Report FD Grip RII-Type Work Inspection Report 19ED Grip R: e Work Inspection Report Project Name: Steel bar : Date of Inspector Clamping Diameter : Grade Inspection Name Machine toe ale fi 2 |@ ia Dz gauge Daz D25 29 32 ‘Tolerance be 110 121 137 154 aMtTiiae (gg~126) | (109~139) | (124~157) | (139~177) Dz | 345 38.5 45.0 50.0 +2%, “6% Number of Clamping work done ____pes. Ttapectins Pace, Sleeve Length | Marking D2 Scale Visually Gauge 1 mm| Pass/Fail | Pass/Fail 2 mm| Pass/Fail | Pass/Fail 3 mm| Pass/Fail | Pass/Fail 4 mm| Pass/Fail | Pass/Fail 5 mm| Pass/Fail | Pass/Fail 6 mm| Pass/Fail | Pass/Fail 7 mm| Pass/Fail | Pass/Fail 24€Inspect 3pcs in the beginning of the work. 4pcs additional inspection in 1 day. Comments: PT. FUJIBOLT INDONESIAFD Grip RII. e Work Inspection Report Project Name? Steel bar Date of Inspector Clamping ” Diameter : Grade Inspection Name Machine U D (om) L D D Gage ae 157.4 48.4 66 (142~196)_|_(46.0~49.3) ‘Torolance | 10%, +25% | +2%, -5% 7 Number of Clamping work done pes, Hee Sleeve Length | | Marking D Scale Visually Gauge 1 mm| Pass/Fail | Pass/Fail 2 nm| Pass/Fail | Pass/Fail 3 mm| Pass/Fail | Pass/Fail 4 nm| Pass/Fail | Pass/Fail 5 mm| Pass/Fail | Pass/Fail 6 mm | Pass/Fail | Pass/Fail 7 nm| Pass/Fail | Pass/Fail Inspect 3pcs in the beginning of the work. 4pcs additional inspection in 1 day. Comments: PT. FUJIBOLT INDONESIA REFROVES-EY PREPARED E TESTED SY a EE, ar SSS TLTANT ——SONTRAGTOR7.2 Qualification Certificate Staffs who do the actual mechanical joints work at site shall have qualification certificate as shown below. Prior to the work, the Engineer will check the qualification certificate. [Link] INDONESIA [Link] INDONESIA gD eb Drea GN Dow. s omy cote nat ore alto Jt ws 3S rad fart wat ths coat. Mis Src sronbed ease FOS Soke ethos his eomcate Te A R . nae oe oa ee comeeee 201603 Bo commen 2016/93 & ——_—_<_$—_— [Link] INDONESIA [Link] INDONESIA GAMBANG NOVEBRIANTO JAJANG ABDUROHIM Twe - = Re contin ane 2016/9/3 = 2073 Material Brochure 24| er or ere ne ns i if at = O a 5 — Ses LiIntroduction ‘Along with the growth of the building industry, advances in high-rise building construction, rapid progress of infrastructure work in Indonesia and innovation in architectural creations, many industries are offering breakthrough products catering for the building industry. The FD Grip Systems produced by PT FUJI BOLT INDONESIA are mechanical joints for deformed steel bars for civil engineering and construction, and they are to replace the overlap method with the mechanical joint. We have a number of product lines, namely type A, B, H, A, M and S. Each has unique properties to ensure high security in different construction applications. Many of our products are cast in concrete, and thus are not noticed by the general public. White not visible, their presence maintains the integrity of building structures for many years. FD Grip Systems offer outstanding strength, efficiency and reliability, along with affordability. ‘These products have been tried and tested in many areas of civil engineering and construction in Japan. They are used in many important high-rise structures, housing complexes, bridges, roads, railways, ports, airports, and power plants. We continuously test new materials and develop new products to meet market, requirements. We are very conscious of research and development to become the best in the industry. What is Fuji Bolt? MECHANICAL JOINT Connections for reinforced steel in building construction have been reliable proven for more than halt a century and still ensure safety and security. EFFICIENCY The Fuji Bolt Joints are easy to install with no skilled labor required. Reduces the amount of waste reinforced steel (compared to overlapping joint system). STRONGNESS The strength of Fuji Bolt Joints was examined by the tensile strength test of the connections. The results show that the reinforced steel breaks - not the bolts.# a3 = This type is specifically created as a connection that can be clipped directly onto reinforced steel on location. Low cost and high quality for structural reinforced steel that demonstrates the expansion ability. Installation steps: 1. Prepare reinforced steel & sleeve, 2, Puta stamp on the reinforced ste! 3. Insert the reinforced steel sleeve, 4, Clamp all surfaces of the sieeve with a clamping machine 5. Check the clamping quality carefully with a gauge, and check both ends of the entry stamp mark on the sleeve connection The machine clamp enables connections through the gaps between reinforced steel in narrow conditions and other ifficult situations. The machine clamp can clamp joints between reinforced steel with diameters from D13 to D35 (8 size diameter reinforced steel). Connect steel bars of different diameters up to 1 level in size. ‘As no heating techniques are required, cold weather and rain do not affect the splicing process of reinforced steel Construction uses hydraulic pumps and an engine brace. The hydraulic pump is Mounted on wheels 80 itis easy to move. i r qae The machine clamp does not require skiled (I I a I (Ie a labor and is easy to use in the field (mm) 249 Sta) 995 99) (M45 [50S [565 Go 405,20Some buildings supported by Fuji Bolt proved earthquake resistantPT. FUJI BOLT INDONESIA Head Office: J Danau Sunter Barat Blok A jl No. 38-99, Jakarta 149% Telp. (021) - 6471 2566, Fax. (021) - 6450 384, e-mail: fh INDONESIA Factory: Ji Wanaherang, BT.04 AW.01, Kee, Gunung Putri, Bogor Tolp./Fax. (021) - 8686 2907 Home-page way fuibolt;comvlidindex html