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MANUFACTURING PROCEDURE FOR A BRIDGE

“THICKENER Ø28m - KODIERAN PROJECT”

CREATED BY:
REV Nº: “A”
W.A.A
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1. INTRODUCTIÓN

This manual is intended to show the sequence and basic steps to be followed for
manufacturing and assembling a bridge.

It should be noted that these procedures and the manufacturing sequences of the bridge
illustrated herein may vary depending on the design and requirements thereof.

2. MAIN PARTS OF A BRIDGE

5
4

3 

2 6
7 
1 

KEY:

1. Bridge Section 1.
2. Bridge Section 2. 6. Feed Pipe Supports.
3. Bridge Section 3. 7. Flocculant Pipe Supports.
4. Handrails.
5. Grating.
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3. PREVIOUS TASKS

A Before the manufacturing process begins, the design and manufactured parts blueprints
must be drawn. All specified and necessary materials shown in the blueprints must be
accounted for.

4. GENERAL CONSIDERATIONS

 Entire supply of steel must be in accordance with the ASTM A-36 Norm, unless otherwise
indicated.
 All plumbing must be in accordance with the ASTM A-53 Norm, unless otherwise
indicated.
 All flanges must be in accordance with the ANSI B16.5 Class
150 Norm, unless otherwise indicated.
 All bolts will be supplied according to ASTM A-325 Norm or equivalent,
unless otherwise indicated.
 All welded joints shall be made according to the AWS D1.1 Norm
 All structures will be surface prepared according to the SSPC
SP-5 Norm (White Metal).
 A painting system must be applied according to the requirements and specifications of
the Project.

5. IMPLEMENTATION PHASES – BASIC CONSIDERATIONS

5.1. Tracing and template use

Before tracing, all dirt and impurities that have adhered to the surface to be traced must be
removed.

The trace for cutting on plates and profiles must be done by qualified personnel, conforming
to the dimensions on the design and manufacturing blueprints; with the tolerance set by
them. The final diameters of each perforation and its exact location must be indicated.

The templates are necessary to verify the curvature diameter that the curved plates must
have and also to give the correct inclination to the manufactured parts at the time of
assembly according to each case. Templates must be made of a material that does not
warp or deteriorate during handling, 1/32” thick plates or similar may be used.

5.2. Cutting

The cutting procedure is used so that the pieces have their final dimensions. Cutting may
be done by sawing, shearing, disk or flame cutting machine. Electric arc cutting is not
allowed.
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The use of shears is allowed only for plates of a thickness no more than 15 mm.

The flame cutting machine is allowed only when the necessary precautions are taken to
achieve a regular cut. And the stresses or transformation produced by thermal origin cause
no inconvenience.

Adhered oxide and burrs, irregular edges and striations produced during cuts, will be
subsequently removed by grinding stone, chisel and subsequent grinding, brush or milling
cutter, finished with fine grinding. This operation must be done carefully on the structure
parts that will be subjected to dynamic loads.

The flanges will be made with the dimensions and angles marked on the blueprints. The
implementation recommendations are to use an automatic flame cutting machine or
machine tool with these requirements, allowing later grinding and burr.

All incoming edges must be left with no sharp edges, rounding them to the largest radius
possible.

5.3. Drilling

The holes for the bolts will be drilled with a drill and the use of a punch tool will be
authorized only in specific cases.

It is recommended that, wherever possible, the perforations

that cross two or more pieces after assembly, be drilled at once, by stapling them or
screwing them together strongly. After drilling, the parts are separated to eliminate
burrs.

Drilling will be generally conducted to a final diameter, except for the perforations in which it
is likely that rectification will be necessary in order to match.

The rectification of the perforation of a seam, if necessary, will be done by a mechanical

reamer. It is prohibited to do so by drill bit or round file.

5.4. Curving or folding

Curving or forming should take place preferably in cold.

It is not admitted that the product have any dent due to compression, or cracks due to
traction produced during curving or folding.

The formation may be in the cold when the plate thickness does not exceed 9mm or the
curvature radius is no less then 50 times the thickness.

The straightening operation on profiles and curved and folded plates will be preferably done
in cold using machine roller or press.
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If exceptionally done in the heat, the following steps are to be followed:

a) Heating is performed, if possible, in an oven. Heating by a furnace or stove is allowed. It

is not convenient to heat directly with a torch. Cooling must be done in still air, without
artificially accelerating it.

b) It will be heated to a maximum temperature of 950ºC(light cherry red), interrupting the

operation when the temperature drops below 700ºC (shadow red), to heat the piece once
again.

c) All necessary precautions will be taken in order not to alter the structure of the steel, or
introduce parasite strains during the stages of heating and cooling.

5.5. Mounting, pre-assembly and Dimensional Control

The objective of this operation is to assemble each of the manufactured parts with its exact
dimensions in the corresponding position that they will have once the final connections are
made.

In order to fix the pieces together "spot welds" can be used; placed between the edges of
the pieces to be joined. The number and size of the spot welds will be the minimum
necessary to ensure immobility.

These weld spots can be included in the final weld if they are perfectly cleaned of slag, and
they don`t have cracks or other defects, subsequently the extreme craters must be filed
with a burin.

When assembled it must be verified that the layout and dimensions of the elements are the
same as those shown in the blueprints; by conducting a thorough Dimensional Control. All
pieces that do not allow assembly under the above conditions must be rectified or remade.

5.6. Welding

Once the correct assembly is finished and accuracy has been verified, we proceed to the
final union of the parts that make the pieces that must be taken already assembled to the
work site location. The pieces to be joined by welding must be fixed together by adequate
means to ensure, without excessive coercion, immobility during welding and subsequent
cooling to achieve position accuracy and facilitate welding. All joints will be prepared
according to the type of welding required and indicated in the blueprints. Everything will be
according to the AWS D1.1 Norm unless otherwise indicated.

Non Destructive Testing

100% of the welded joints will be subject to liquid penetrating tests and 20% of the welded
joints will be subject to gamma graphical tests
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Repairs due to non compliance or Weld rejection:

 If the result of a non destructive test is rejection, the following procedure will be to
grind, clean and re-weld.
 After repairing, complete tests are to be conducted again until the defect (crack, lack
of penetration, lack of fusion, undercutting, etc.) completely disappears or is
tolerated under the AWS D1. Norm.

Non-Destructive Testing Non-Destructive Testing

Liquid Penetrate Gamma graphical Testing
 

5.7. Surface Preparation

All structural elements must be provided with surface preparation and corresponding
primers unless otherwise particularly specified. All surfaces must be thoroughly cleaned,
eliminating all traces of dirt, oxide scale, welding slag or drops by abrasive blasting so that
the piece is completely clean and dry.

Surface preparation must follow the SSPC

SP-5 Norm(Steel Structure Painting
Council), unless otherwise indicated.

The surface looked upon without

augmentation must be slightly roughened
to form an adequate profile that allows
good anchorage for coatings. The
roughness of the steel surface must be of
approximately 100 microns and must be
measured to give conformity of proper
surface preparation.

Roughness Measurement
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5.8. Paint

Strict compliance to the specified paint system for each component must be applied
depending on whether it will be working in continuous immersion or under environmental
conditions. The paint type, color, dry coat thickness and finishing will be taken into account.

The visual inspection must verify that there are no bubbles and no draining or dripping of
the paint.

The tensile adhesion test must be executed according to the ASTM D4541 Norm and the
minimum value required will be 500 psi. It will be carried out when the curing of the paint
has concluded in a period of no less than 15 days.

The wet film thickness must be measured with a stainless gauge and the dry thickness
must be measured with an ultrasonic thickness meter.

Tensile adhesion test results and total EPS

 

 
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6. ASSEMBLY PROCEDURE - BRIDGE

6.1 MATERIAL PREPARATION

1. Cut upper and lower longitudinal beams.

2. Make all necessary perforations on the longitudinal beams.

3. Manufacture all clamping plates and make all necessary perforations.

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4. Cut columns and vertical diagonals.

5. Cut horizontal diagonals and beams.

6. Cut the union diagonals of sections of the bridge and then weld them to the clamping plates.
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6.2 BRIDGE MANUFACTURING SEQUENCE

1. Place leveled caps on the floor to shape the counter shaft (camber) as indicated in
the layout.

2. Join the three sections of the lower longitudinal beams with the clamping plates.
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3. Lift the three sections of the lower longitudinal beams and place them on the caps fixing them
with welding spots.

4. Join the lower beam with uprights and diagonals.

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5. Join the superior beam (previously prepared according to the procedure described in point
Nº2) to the uprights and diagonals.

6. Flip the assembled pieces and weld the upper beam horizontally

7. Repeat the operation for the second module.

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8. Place lower cross beams and lower horizontal diagonals.

9. Place upper cross beams and upper horizontal diagonals.

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10. Place lateral frames and then bolt them to the clamping plates.

11. Place and weld support for drive frame.

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6.3 FLOCCULANT PIPE SUPPORT, HANDRAILS, GRATING AND FEED PIPE SUPPORT

1. Weld the flocculant pipe brackets to the bridge.

Brackets 

Brackets 

2. Weld the grating angle brackets and the handrails. Pre-assemble the grating and handrail to
the bridge.
Grating 

Handrails 

Brackets 
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4. Weld the Feed Pipe brackets.

Brackets

7. BRIDGE FINISHED