Ain Tsila Development

Main EPC Contract

A-CNT-CON-00282

SPECIFICATION FOR STRUCTURAL STEEL

FABRICATION AND ERECTION
A-CIV-SPE-000-30007

This document is developed based on Doc No.

A-CIV-SPE-000-00002, Rev 04 of FEED

0 Issued for Design 11-June-2019 MH AAR RA MTS

A Issued for Approval 29-May -2019 MH AAR RA MTS

Rev Purpose Date Prepared Checked Approved Approved

 Specification for Structural Steel Fabrication and Erection
Document No : A-CIV-SPE-000-30007
Revision 0

Document Owner: Information Manager

REVISION HISTORY
Revision Changes

A Issued for review and approval

0 Issued for Design

This revision checked and signed off by:

Name Function or Job Title

Manas Halder (MH) Senior Engineer (Civil & Structural)

Arjun Rawat (AAR) Deputy Manager (Civil & Structural)

Ruhul Amin (RA) Lead Engineer (Civil & Structural)

Mohammed Tariq
Engineering Manager
Siddiquie (MTS)

Holds
Hold No. Location Description

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Contents

1 INTRODUCTION 5
1.1 Purpose 5
1.2 Project overview 5
1.3 Scope 5
1.4 Regulatory requirements 5
2 REFERENCES 6
2.1 Related engineering specifications and document 6
2.2 Algerian regulations 6
2.3 Codes 6
2.4 Order of Precedence 8
2.5 Standard drawings 8
2.6 Units 8
3 DEFINITIONS 9
4 DESIGN 9
5 MATERIALS 10
5.1 Structural steel and steel pipe 10
5.2 Bolts, nuts and washers 10
5.3 Welding materials 11
5.4 Certificates 11
6 CONNECTIONS 12
6.1 General 12
6.2 Bolted connections 13
6.3 Bracing 14
6.4 Drainage holes 14
6.5 Detail calculations of connections 14
7 DRAWINGS AND CALCULATIONS 14
7.1 General 14
7.2 Marking plan drawings 16
7.3 Shop drawings 17
8 FABRICATION 17
8.1 General 17
8.2 Workmanship 18
8.3 Welding 19
8.4 Inspection and testing 20
8.5 Inspection of cold formed components and sheeting fasteners 21
8.6 Surface protection 22
8.7 MARKING 22
9 PACKING, TRANSPORTATION AND STORAGE 23
9.1 General 23

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9.2 Receipt of material 24

10 ERECTION 24
10.1 Erection method statement 24
10.2 Erection drawings 25
10.3 Field welding and flame cutting 25
10.4 Assembly 27
10.5 Tightening of Bolts 29
10.6 Tolerance and corrections 30
10.7 Safety 30
10.8 Field painting 30
11 FIELD INSPECTION 30
12 QUALITY CONTROL 31
12.1 Quality system 31
12.2 Material 31
12.3 Fabrication / receipt / storage 31
12.4 Erection 32
12.5 Final inspection 33

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1 INTRODUCTION

1.1 PURPOSE
The scope of this specification is to identify the minimum quality and technical
requirements for materials, equipment, labour, inspection, and necessary testing to
accomplish the fabrication, to deliver and to erect the structural and miscellaneous steel.

1.2 PROJECT OVERVIEW

Groupement ISARÈNE (the “COMPANY”) will develop the Ain Tsila gas field which is
located in the Illizi basin in the eastern part of the Sahara Desert in south-east Algeria,
south of the Grand Erg Oriental. The field was discovered within the Périmètre Isarène
(Blocks 228, 229a) in 2007 and has been appraised to hold approximately 65 billion
cubic metres (2.29 trillion cubic feet) of recoverable hydrocarbon reserves. The field lies
in the Sahara Desert, approximately 1,100km south-east of Algiers, 175km west of In
Amenas, 175km north- west of Illizi and 450km to the south-east of Hassi Messaoud.
Central Processing Facility (CPF) is designed to produce 10.3 MMSCMD sales gas.
A gathering system, comprising wellsites, wellsite systems, flowlines, manifold stations
and trunk pipelines to gather the produced fluids and transport them to the reception
facilities at the CPF. Raw gas will be treated in the CPF. Processing facilities comprising
pipeline reception facilities, slugcatcher(s), feed gas compression, mercury removal, gas
dehydration, gas conditioning (natural gas liquids extraction), export compression,
condensate stripper, LPG fractionation facilities, condensate and LPG export facilities
and associated utilities, storage and buildings (all located at the CPF). Fiscal metering
for sales gas, LPG and condensate, located at the CPF battery limit.
Sales quality gas will be delivered to SONATRACH TRC’s (TRC) sales gas pipeline
system at a tie-in point on a manifold next to the TFT compressor station. Liquefied
petroleum gas (LPG) will be delivered to TRC’s LPG pipeline system at a tie-in point
located at a block valve station west of the TFT compressor station. Stabilised
condensate will be delivered to TRC’s condensate pipeline system at a tie-in point
located at Méderba, approximately 165km north of Ain Tsila.

1.3 SCOPE
This Specification covers the minimum requirements for the materials, fabrication and
erection of steel frame buildings (defined as an enclosed structure), steel structures,
supporting steel for equipment, steel pipe racks and miscellaneous structural steel, such
as steel platforms, stairs, ladders, grating, trolley beams, etc., but excluding steel (sheet)
piling and fencing.

1.4 REGULATORY REQUIREMENTS

For subjects not covered by regulations, codes and standards or specifications, the
materials and execution of the work shall be based on good economical engineering
practice.
All drawings and computations including for connections shall be submitted to the
Organisme National de Controle Technique de la Construction (C.T.C.) for approval prior
to fabrication and construction of steelworks.

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C.T.C. may carry out site visit’s to inspect the preparation of steel structures and inspect
the erection of the steel work.
The CONTRACTOR shall agree the requirements and procedures for submission and
approval of documentation and for the visits and shall conclude a contract with C.T.C.
for their services.

2 REFERENCES

2.1 RELATED ENGINEERING SPECIFICATIONS AND DOCUMENT

A-CIV-BOD-000-30001 Civil and Structural Design Basis
A-CIV-SPE-000-30008 Specification for fire proofing of Structural Steel.
A-MTL-SPE-000-0000730003 Specification for Surface preparation and painting

2.2 ALGERIAN REGULATIONS

Ministeres des Travaux Recueil des Normes Algériennes. Secteur des
Publics travaux publics

Organisme National de Référentiel technique et réglemetaire de la

Contrôle Technique de la construction
Construction

2.3 CODES

2.3.1 Algerian Codes

D.T.R. C - 2.47 Règlement neige et vent “R.N.V. 2013”
D.T.R. BC - 2.48 Règles parasismiques algériennes “R.P.A. 99” version 2003
Règles de conception et de calcul des structures en acier
D.T.R. BC – 2.44
“CCM 97”

2.3.2 European Codes

Welding consumables – Solid wire electrodes, tubular cored
EN ISO 14171 electrodes and electrode/flux combinations for submerged arc
welding of non alloy and fine grain steels - classification

2.3.3 British Codes

BS EN 1090 Execution of Steel Structures and Aluminium Structures
BS EN 10020 Definition and classification of grades of steel
BS EN 10025 Hot-Rolled Products of non-alloy Structural Steel
BS EN ISO 9692-1 Welding and allied processes. Recommendations for joint
preparation. Manual metal-arc welding, gas-shielded metal arc
welding, gas welding, TIG welding and beam welding of steels.
BS EN 287-1 Approval testing of welders for fusion welding
BS EN ISO 2560 Welding consumables. Covered electrodes for manual metal arc
welding of non-alloy and fine grain steel. Classification

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BS EN ISO 3834 Quality Requirements for Welding – Fusion welding of metallic

materials.
BS EN 1011 Welding- Recommendations for Welding of Metallic Materials.
BS EN 10204 Metallic materials – Types of inspection documents.
BS EN 10210 Hot finished Structural Hollow Sections of non-alloy and fine-
grained Steel
BS EN 10034 Structural Steel I and H sections: Tolerances in shape and
dimensions.
BS ISO 68-1 General purpose screw threads – Basic profile- Metric Screw
Threads.
BS EN ISO 15609 Specification and Qualification of welding procedures for metallic
materials- Welding procedure Specification.
BS EN ISO 14341 Welding consumables – wire electrodes and weld deposits for gas
shielded metal arc welding of non alloy and fine grain steels -
classification
BS ISO 261 General purpose metric screw threads – General Plan.
BS EN ISO 898-1 Mechanical properties of fasteners made of carbon steel and alloy
steel – Part 1: Bolts, screws and studs.
BS EN ISO 898-2 Mechanical properties of fasteners made of carbon steel and alloy
steel – Part 2: Nuts with specified property class
BS EN ISO 17635 Non-destructive testing of welds. General rules for metallic
materials
BS EN 10346 Continuously hot-dip coated steel flat products. Technical delivery
conditions
BS ISO 4035 Hexagon thin nuts chamfered (style 0). Product grades A and B
BS ISO 4034 Hexagon nuts – Product grade C
BS ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles –
Specifications and test methods.
BS EN ISO 5182 Resistance welding – Materials for electrodes and ancillary
equipment.
BS EN 15048 Non-preloaded structural bolting assemblies
BS EN ISO 1460 Metallic coatings. Hot dip galvanized coatings on ferrous
materials. Gravimetric determination of the mass per unit area
BS ISO 10684 Fastener-Hot dip galvanized coating.

2.3.4 American Codes

ASCE 7 -10 Minimum Design Loads for Buildings and Other Structures
AISC 325 Steel Construction Manual
AISC 360-10 Specification for Structural Steel Building
AISC 303-16 Standard Practice for Steel Building and Bridges
AWS D1.1 Structural Welding Code
ASTM A36M Standard Specification for Carbon Structural Steel
ASTM A123 / A123M Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on
Iron and Steel Products.

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ASTM A153M Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware.
ASTM A307 Standard Specification for Carbon Steel Bolts, Studs and Threaded
Rod.
ASTM A325 Standard Specification for Structural Bolts
ASTM F436M Standard Specification for Hardened Steel Washer inch and Metric
Dimensions
ASTM A563 Standard Specification for Carbon and Alloy Steel Nuts

2.3.5 International Codes

ISO 7089 Plain washers normal series product grade A
ISO 7091 Plain washers normal series product grade C
DIN 434 Square taper washer for “U” -sections
DIN 435 Square taper washer for “I” -sections

2.3.6 If the CONTRACTOR wishes to use an alternative code of practice or standard to

any of those listed above this shall not be permitted without written approval by
COMPANY.

2.4 ORDER OF PRECEDENCE

.
In the event of conflict between the requirements of this specification and other referenced
documents, the CONTRACTOR shall request written clarification from COMPANY. The
order of precedence will normally be:

 Algerian Legislation.
 Algerian Regulatory Authorities Regulations.
 International codes and standards.
 COMPANY Philosophy documents.
 Project Specifications.

2.5 STANDARD DRAWINGS

Project standard drawings as per Technical Document Register shall be referred
structural fabrication and erection.

2.6 UNITS
 Elevations : Metre (m).
 Dimensions : Millimetre (mm).
 Force : Kilo Newton (kN).
 Mass : Kilogramme (kg).
 Moment : Kilo Newton metre (kNm).

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 Stress : Newton per square millimetre (N/mm²) or Mega

Pascal (MPa)
 Pressure : Kilo Pascal (kPa) or kilogramme per square
centimetre (kg/cm²).
 Loadings : Kilo Newton per square metre (kN/m²)
 Temperature : Degree Celsius (ºC)

Units used are multiples and sub-multiples of SI-units.

3 DEFINITIONS
The terms and definitions as used within this document are listed below.

“COMPANY” means Groupement ISARÈNE (the operator of the Ain Tsila

Development)
“CONTRACTOR” means the party, which carries out all or part of the design,
engineering, installation and commissioning, procurement
and construction applicable to this specification
“shall” or “must” indicates that the specified action is mandatory (i.e. must be
done by the specified action party)
“should” indicates that the specified action is recommended but not
mandatory. However the action party will be responsible for
the consequences in the event that he/she elects not to do it

“will” indicates a commitment by others or a statement of fact

“Purchaser” means the entity defined as such in the purchase order or
Contract
“Seller” means the entity defined as such in the purchase order or
contract
“Sub-supplier” means the entity responsible for the supply of components
or services to the Seller
“Manufacturer” means the entity responsible for the manufacture of an item
ultimately supplied by the Seller to the Purchaser
“Goods” means the physical items delivered under the terms of the
purchase order or contract
“Services” means any services provided pursuant to the purchase
order or contract but not incorporated in the Goods

4 DESIGN
The CONTRACTOR shall provide as a minimum the following design documents
approved by COMPANY and C.T.C. to fabrication sub-contractor:

 Project specifications

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 Structural design drawings

 Structural design analysis
These documents shall be provided in order to allow the fabrication sub-
contractor to compile his deliverables and fabrication as set forth in this
specification.

5 MATERIALS

5.1 STRUCTURAL STEEL AND STEEL PIPE

5.1.1 All material shall be new stock and each structural member or column shall be cut
from a rolled or cold formed structural section. No substitution of materials shall be
allowed without written approval from the COMPANY.
For grade of structural steel and steel pipes, refer doc no-A-CIV-BOD-000-30001
(Civil & Structural Design Basis).
Any structural member or column shall be spliced subject to below requirements
 No member less than 4m shall contain splice
 No member shall contain more than one (1) splice.
 Length of spliced member shall be minimum 1.5m
 All splice welds to be carried out in offsite fabrication shop under
controlled environment.

5.2 BOLTS, NUTS AND WASHERS

5.2.1 Each bolt assembly shall consist of one heavy semi-finished hexagon structural
bolt, one heavy semi-finished hexagon nut and one hardened washer, to be used
under the nut. The assembly shall conform to BS EN 15048 or equivalent.
Two nuts are required for structures supporting vibrating equipment and for anchor
bolts.

Hardened washers are required to provide adequate bearing area. Where the
surfaces of bolted parts, which are in contact with the bolt head or nut, have a
slope of more than 1:20 with respect to a plane normal to the bolt axis (e.g.
channels and/or I- beams), a smooth tapered washer shall be used to compensate
for the slope.
The bolt shall be long enough that a minimum of three (3) threads shall be protrude
through the nut.

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5.2.2 Threads of bolts and nuts shall be metric, as per BS ISO 68-1 and BS ISO 261 or
equivalent.

5.2.3 High strength bolts shall conform to EN-ISO 898-1 or equivalent, property class
8.8 or equivalent.

5.2.4 Nuts shall conform to BS ISO 4035 or equivalent, property class A & B.

5.2.5 Nuts shall conform to BS ISO 4034 or equivalent, property class C.

5.2.6 Plain washers shall conform to ISO 7089 and 7091 or equivalent. Taper washers
shall conform to DIN 434 and DIN 435 or equivalent.

5.2.7 Bolts, nuts and washers shall be hot-dip galvanized conforming to BS ISO 1461
sherardized to BS 7371.Bolts and nuts shall be hot-dip galvanized as per BS ISO
10684. Washers shall be hot-dip galvanized as per either BS ISO 10684 or BS ISO
1461.

5.2.8 Where bolts are galvanised or sherardized, nuts of a higher property class shall be
used e.g. for grade 8.8 galvanised bolts the nuts shall be class 10.

5.2.9 The use of different grade bolts of the same diameter should be avoided.

5.2.10 Each bolt and nut assembly shall be supplied by one manufacturer and the bolt
and nut shall be identified with the manufacturers mark. The coating of the nut and
bolt assembly shall be carried out under the control of the manufacturer.

5.2.11 CONTRACTOR shall verify that bolts, nuts and washers are compatible with each
other.

5.3 WELDING MATERIALS

5.3.1 Welding electrodes shall conform to BS EN ISO 14341, BS EN ISO 2560 and BS
EN ISO 5182. Minimum electrode tensile strength shall be 480 MPa.

5.3.2 Materials for submerged arc welding shall conform to EN ISO 14171 or equivalent.

5.3.3 Materials for gas shielded metal arc welding shall conform EN ISO 14341 or
equivalent.

5.3.4 Minimum requirements for welding material, such as yield strength, tensile
strength, etc., shall be the same as for the parent material.

5.4 CERTIFICATES
Mill certification of materials shall be provided for all structural steel materials as
per BS EN 10204 type 3.1 as per Table A.1 annex A, and based on the material
type, the use and requirements.
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6 CONNECTIONS

6.1 GENERAL

6.1.1 All shop connections shall be welded, except shop connections for light platform
framing, etc. which may be bolted. Shop fillet welds shall have a minimum 4 mm
throat thickness. However, if the thickness of the parent material is less than 6 mm,
the minimum throat thickness of the fillet weld can be reduced to 3 mm.

6.1.2 As far as possible, Field assemblies shall be bolted.

6.1.3 Field welding shall be kept to the absolute minimum, especially when parts are
galvanised.

6.1.4 Fabrication sub-contractor shall take into account possible deviations of profile
shapes when working out the theoretical dimensions given on CONTRACTOR’s
design drawings.

6.1.5 Purlins shall be fixed to the roof beams or trusses by means of angle steels. Fixing
purlins by means of bent flats is not permitted.

6.1.6 Double angle members shall have fillers plates at a maximum spacing not more
than 50 times the minimum radius of gyration of the combined assembly.

6.1.7 Gusset plates shall not be thinner than the members to be connected and shall
have a thickness of at least 8 mm.

6.1.8 End plates for a beam shall not be thinner than the flange thickness of that beam.

6.1.9 Columns shall have full bearing at splices and at end plates. Design splices for the
full strength of the column. Weld base plate to column all round, unless otherwise
shown on drawings.

6.1.10 Connections of hand-rails, stairs, ladders, bracing (for angle only), etc., to
fireproofed beam/columns shall be outside the fireproofing.

6.1.11 For splices in structural steel other than those shown on the design drawings,
CONTRACTOR’s approval is required, in writing, prior to starting fabrication. Such

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splices shall be full penetration butt welds. All such splices shall be shown on
fabrication sub-contractor’s shop drawings.

6.1.12 Holes in gusset plates shall be so arranged to minimize moments in beams due to
eccentricity.

6.1.13 Connections shall be designed to avoid entrapment of water. Pockets or

depressions, which could hold water, shall have drain holes or be otherwise
protected.

6.2 BOLTED CONNECTIONS

The use of fully threaded bolts should be considered in preference to part threaded, in
order to reduce the range of bolt lengths specified for steelwork.
The selection of the bolt diameters shall be in accordance with the width of the flanges
and the thicknesses of the sections to be connected.
Bolts designed for transmitting forces in structural member connections, shall have the
diameter as follow:

6.2.1 Minimum Diameter

 For main members, bracings and struts 20 mm.
 For secondary members, i.e. bracings,
purlins, ladders, handrails, etc. 16 mm.
(unless noted otherwise on standard drawings)

6.2.2 Bolted connections shall be made with a minimum of two bolts, except that one
bolt connection between non-stressed tie or bracing members is permissible when
specifically shown on design drawings.

6.2.3 Except otherwise noted on design drawings, hole diameter for bolts shall be as
follows:

6.2.4 Diameter bolt, plus:

 For steel-to-steel connections : 2 mm. < M24
: 3 mm. > M24
 For steel-to-concrete connections (anchor bolts) :
o Up to 24 mm bolt diameter : 4 mm.
o 24 to 32 mm bolt diameter : 6 mm.
o 32 mm bolt diameter and over : 8 mm.

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Spacing of bolt holes shall be as per Chapter J of AISC 325

6.2.5 Slotted hole connections are to be executed in such a way, that these connections
may perform their design function, as indicated on the design drawings, and shall
be provided with washers.

6.2.6 High-strength bolts, grade 8.8, or equivalent shall be used for structural steel-to-
steel connections.

6.2.7 High-strength bolts, grade 8.8, or equivalent shall be used in bearing-type

connections and not as friction grip bolts.

6.2.8 Practical length of bracing under tension shall be shorter than theoretical to give
some pretension after erection.

6.2.9 Burning of steelwork to form or enlarge holes shall not be not allowed.

6.3 BRACING
Suitable deductions shall be made on the theoretical computed lengths in all
diagonal bracing longer than 3 m to provide for draw in order to prevent visible
sagging.

6.4 DRAINAGE HOLES

Drainage holes shall be provided in members where water can collect during and
after erection. Drainage holes shall be 30mm diameter at 1000mm centre to
centre. Reduced areas and sectional properties shall be computed and the
members strengthened as necessary.

6.5 DETAIL CALCULATIONS OF CONNECTIONS

Standard Connection details with related calculations shall be prepared by
ContractorCONTRACTOR as per AISC 325 and will be provided to fabrication sub-
contractor

7 DRAWINGS AND CALCULATIONS

7.1 GENERAL

7.1.1 Shop drawings shall include clear position and mark numbers. Shop drawings shall
have cross-references to the mark drawings and erection drawings. Each shop
drawing shall have a key plan, indicating mark numbers made from that drawing.

7.1.2 Shop drawings shall show position, mark and bolt, washer, nut and shim lists with
reference to the shop drawings, mark drawings, erection drawings and design
drawings. Bolt, washer, nut and shim lists have references to the marks that are to
be bolted together.
Approved templates shall be used for preparation of Fabrication drawings.

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7.1.3 The shop drawings shall only be started on the basis of the “ Issued for
Construction (IFC) CONTRACTOR’s design drawings and design calculations.

7.1.4 The shop drawings shall be in accordance with:

 Algerian regulations / codes.
 IFC design drawings.
 IFC design calculations.
 International Standards and specifications.
 “For Purchase” steel subcontract.

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7.1.5 The shop drawings shall follow as per approved schedule by the CONTRACTOR.

7.1.6 The fabrication sub-contractor shall provide a regular updated drawing list, during
preparation of shop drawings, with the latest revisions.

7.1.7 Units for dimensions and elevations shall be similar to the units as given on the
CONTRACTOR’s design drawings.

7.1.8 All shop drawings and documents which have to be submitted to the authorities
shall be presented in appropriate language as per Purchase order.

7.1.9 A list with a description of all used abbreviations shall be given on at least one
drawing. For the other drawings, a reference to that particular drawing is sufficient.

7.1.10 Grade of used materials shall be given on the drawing (e.g. grade of steel, grade
of bolts).

7.1.11 The applied surface preparation, with reference to the applicable specification,
shall be given on the drawing.

7.1.12 Revisions on drawing shall be clouded with an indication of the revision number in
a triangle or as per Project guidelines. After a new issue previous clouds and
revision number shall be removed.

7.1.13 The sub-contractor shall provide a bolt list for steel-to-steel connections.

7.1.14 When CONTRACTOR require bolts for fixing equipment on steel, fabrication sub-
contractor shall provide a bolt list for these bolts as well.

7.2 MARKING PLAN DRAWINGS

7.2.1 A marking plan shall show the locations, elevations, marks and profile sizes of all
members, handrail, ladders, stairways, etc.

7.2.2 A marking system shall follow the AISC standard or a similar system as approved
by CONTRACTOR.

7.2.3 All items which shall be assembled on site shall be marked.

7.2.4 References shall be made to CONTRACTOR’s design drawings, design

calculations and fabrication sub-contractor’s relevant shop drawings.

7.2.5 Preferably relevant shop drawing numbers shall be incorporated in the marking
numbering system.

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7.3 SHOP DRAWINGS

7.3.1 Shop drawings consist of:

 Detailed member drawings, including details of connections.
 Handrail drawings.
 Ladder and stairway drawings.
 Wall cladding and roof cladding drawings.
 Floor panel drawings, with holes if applicable (grating, raised pattern plate, etc.).
 Other detailed drawings.

7.3.2 Top of steel elevations of all members shall be given on the shop drawing, as
specified on the applicable design drawings.

7.3.3 Reference dimensions on the applicable design drawings shall be given on the
shop drawing. Therefore, all dimensions and elevations as given on the design
drawings shall be duplicated on the shop drawings.

7.3.4 For floor panels the span direction and location of splices for holes shall be given
on the shop drawings.

7.3.5 Deviations from the design drawings shall only be permitted after written approval
from CONTRACTOR.

7.3.6 Scheme lines for connections shall be given on the shop drawing in accordance
with design drawings.

7.3.7 The sizes of all used shapes shall be given on the shop drawing.

7.3.8 Reference shall be made to the relevant marking plan drawing (s).

8 FABRICATION

8.1 GENERAL

8.1.1 Fabrication shall be in accordance with code AISC guidelines or BS EN 1090-2,

including all codes referenced therein.

8.1.2 At all stages of fabrication each member or component shall be identifiable.

8.1.3 The size of members indicated on design drawings shall be strictly followed.
However, where the fabrication sub-contractor has difficulty in obtaining the

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specified section size, an alternative size may be substituted subject to

CONTRACTOR’s approval in writing before substitution.

8.1.4 All welding shall be in accordance with the requirements of code BS EN-ISO 3834
1, 2, 3 & 4 and BS EN-1011 1, 2, 3 & 4/ AWS D1.1 or equivalent international
standard. Welding shall only be carried out by suitably qualified welders.

8.1.5 Edge preparation (bevelling) for V, X, K or U- welds shall conform to relevant

welding code.

8.1.6 Punching of holes in structural members transmitting forces is not allowed.

CONTRACTOR’s approval, in writing, is required for punching holes in other
members than mentioned above.

8.2 WORKMANSHIP

8.2.1 The workmanship and finish shall be equal to the best in modern shop practice
and shall be in accordance with regulatory requirements.

8.2.2 Only new material shall be used, which shall be straightened in the shop by
methods that will not cause damage before it is laid off or worked in any way.

8.2.3 All cutting and shearing shall be neatly done and all surfaces/edges exposed to
view shall have a neat and workmanlike finish. Sharp edges shall be removed and
rounded off with a minimum radius of 1 2 mm.

8.2.4 Structural steel elements shall be constructed plumb and level and shall be aligned
within the tolerances in accordance with AISC.

8.2.5 Horizontal beams placed in such a way that they form rain pockets shall be
provided with drain holes of 30 mm diameter, centre to centre 1000 mm, with a
minimum of two holes.

8.2.6 It shall be fabrication sub-contractor’s responsibility to ensure that any excessive

warp or distortion of structural steel caused by galvanizing shall be corrected by
means of straightening prior to shipment.

8.2.7 Stairways, ladders and hand-rails shall be in accordance with the standard
drawings. Ladders, stairs and platforms shall be assembled in the shop to the

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largest dimensions possible. Fabricator when performing shop assembly work,

shall not exceed the tolerances specified in AISC 303-16.

8.3 WELDING

8.3.1 The CONTRACTOR shall carry out welding operations in accordance with the
requirements of BS EN 1090-2 or AWS D1.1. Verification of all welding shall be as
per clause no-8.1.4 of this document.

8.3.2 Fabrication sub-contractor shall, within one week after notification of award of
contract, provide welding procedures for comment and/or review. Review of
welding procedures by CONTRACTOR and COMPANY is required before the start
of welding.

8.3.3 The welding procedure shall be qualified using the same material, process and
type of equipment to be used for production. The welder shall be tested to meet
the requirement of BS EN 287 or equivalent. If the welder performing the
production welding is not the same welder used in qualification of the procedure,
he shall be qualified separately.

8.3.4 Prior to start of welding, fabrication sub-contractor shall submit to CONTRACTOR

for approval copies of all welders’ qualification papers, both for shop and field
welders.

8.3.5 Electroslag welding and electrogas welding procedures shall not be used for
structural steelwork.

8.3.6 Welding shall be of good quality and shall comply with the requirements of
applicable codes. All welders employed shall be tested for the required procedure
in accordance with the applicable regulations. Test samples of all tests shall be
available for inspection.

8.3.7 All welding shall be an arc process in accordance with BS EN 1011-1 or equivalent.
All welding procedures submitted shall be qualified by tests in accordance with BS
EN ISO 15609 or equivalent and shall comply with the guidance of BS EN 1011-2
or equivalent.

8.3.8 Joints shall be prepared in accordance with BS EN ISO 9692 or equivalent.

8.3.9 Welding starts and stops on all passes shall be held to a minimum. When starts
and stops are unavoidable, each position shall be properly conditioned before
proceeding with the adjacent welding. The use of starting and stopping plates is
recommended.

8.3.10 All fillet welds shall be minimum 4 mm. However, if the thickness of the parent
material is less than 6mm, the minimum throat thickness of the parent material

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weld can be reduced to 3 mm. Field connections shall be avoided wherever

possible.

8.3.11 All welds shall be visually inspected after completion. Welds shall be free of cracks,
excessive porosity and slag inclusion and undercutting. The weld acceptance
criteria shall be as per the appropriate international code/standard.

8.4 INSPECTION AND TESTING

8.4.1 All structural steel materials and fabrication shall be subject to inspection by
CONTRACTOR. All inspections shall be carried out by suitably qualified personnel
and shall be documented and recorded.

8.4.2 All connections shall be visually checked when they have been tightened after the
structure has been aligned locally.

8.4.3 A minimum 10% check of bolt fastenings in each connection shall be carried out
by the CONTRACTOR. Any connection that is found to contain loose bolts shall
be subject to a full inspection.

8.4.4 After checking and acceptance of a connection, the erection drawing shall be
marked to indicate acceptance.

8.4.5 CONTRACTOR’s inspector shall have free access to the materials and to all parts
of the steel structure which is being fabricated. Material which is found to be
defective or contrary to this specification and requirements of the purchase shall
be rejected.

8.4.6 Where pre-erection is specified, the members of the structure or parts thereof shall
be laid out on the shop floor for inspection.

8.4.7 Welds shall be inspected by CONTRACTOR’s inspector according to the

provisions of code BS EN ISO 3834-2 or equivalent with respect to technique,
equipment, acceptance criteria and personnel qualifications. All welds shall be
subject to visual inspection by CONTRACTOR’s inspector throughout their entire

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length. In addition, the following special requirements shall apply to welding

inspection.

8.4.8 In order to verify that welding procedures are producing conforming welds, routine
testing shall be carried out as required by EN 1090 part 2 or equivalent.

8.4.9 Non-destructive testing methods shall be carried out in accordance with BS EN

ISO 17635 or equivalent. All NDT procedures shall be submitted to
CONTRACTOR for acceptance prior to work commencing.

8.4.10 All critical butt welds shall have a full visual inspection and shall also be inspected
by either radiographic or ultrasonic methods as follows:
 Radiographic:
Make one spot radiograph per 500 mm of butt weld. Take the radiographs
on the flange sections of the beam with a minimum of one radiograph per
welded connection, in accordance with relevant regulatory requirements.
 Ultrasonic:
Entire length of butt weld, including the webs, shall be tested. The ultrasonic
examination shall be done in accordance with regulatory requirements.

8.4.11 All full penetration corner and T-joint welds, used in beam column connections
shall have full visual inspection and shall also be inspected by ultrasonic methods
in accordance with the thickness schedule below:
Thickness of thinnest section being Percent of weld length to be tested
welded
Less than 25 mm None
25 mm to 50 mm 5
Over 50 mm 20

8.4.12 All fillet welds size 25 mm (leg length) or over in size shall be inspected by
magnetic particle testing or liquid penetrant inspection for 10% of their length.

8.5 INSPECTION OF COLD FORMED COMPONENTS AND SHEETING FASTENERS

8.5.1 Where self-tapping or self-drilling screws are used, sample holes shall be
measured periodically by spot checks to ensure that they are in accordance with
the manufacturer’s recommendations.

8.5.2 Sample screws shall be checked periodically to verify thread integrity after
installation. Screws which exhibit a deformation of thread exceeding the limits

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given by the fastener manufacturer shall be replaced with new fasteners in

accordance with the requirements of the manufacturer.

8.5.3 For blind rivets sample holes shall be measured periodically by spot checks to
ensure that they are in accordance with manufacturer’s recommendations.

8.5.4 Holes with burred edges which could adversely affect the drawing together of the
connected parts shall be rectified before the rivet connection is made.

8.5.5 Cartridge fired pins shall not be permitted without written approval from
COMPANY. Where approval has been given inspection shall be carried out to
ensure that no pins have been under-driven or over-driven and that the
manufacturer’s mark on the pin is still recognisable after the pins have been driven.

8.6 SURFACE PROTECTION

8.6.1 All structural steel except grating, stair treads and raised pattern plate and steel to
which fireproofing treatment shall be applied, shall receive a complete painting
system or shall be galvanised.

8.6.2 Surface treatment, painting system and galvanisation shall be in accordance with
project specification be treated in accordance with the project specification A-MTL-
SPE-000-30003 “Specification for Surface preparation and painting”.

8.6.3 Bolts, nuts and washersBolts and nuts shall be hot-dip galvanized as per BS ISO
10684. Washers shall be hot-dip galvanized as per either BS ISO 10684 or BS ISO
1461, grating, stair treads and raised pattern floor plate shall be hot-dip galvanized
in accordance with BS ISO 1460 and BS ISO 1461 or ASTM 123/123M. The
average weight of the zinc layer shall be 610 g/m2 of galvanized surface for
sections not less than 6 mm thick, equivalent to an average coating thickness of
85 µm.

8.6.4 If a galvanized coating is damaged, repair shall be done in accordance with the
project specification A-MTL-SPE-000-30003 “Specification for Surface preparation
and painting”.

8.6.5 Before painting or galvanising all structural steel items shall receive surface
preparation (blasting and cleaning) accordance with the project specification A-
MTL-SPE-000-30003 “Specification for Surface preparation and painting”.

8.6.6 Grating, stair treads and raised pattern floor plate shall be hot-dip galvanised.

8.7 MARKING

8.7.1 All structural steel members, grating, hand-rails, stairways, stringers, stair treads,
etc., shall be marked with identification marks and such other marks as may be

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required to facilitate erection in accordance with the marking diagram provided by

the fabrication sub-contractor. Marking paint must be compatible with primer or
finish coat.

8.7.2 Erection marks shall be clearly painted with a white weather-resistant paint on all
structural members and loose parts (except grating) in symbols at least 50 mm
high. In addition, they shall be stamped on all structural members, in symbols at
least 12 mm high and 1 mm deep.

8.7.3 Painted marking shall not be applied until the final paint coat is thoroughly dry or
after galvanizing.

8.7.4 Marks will have references to the relevant mark and erection drawings and to the
relevant bolt-nut-washer shim lists.

8.7.5 Marking will be done on the same locations as the marks shown in the mark and
erection drawing(s).

8.7.6 All members to be marked “TOP” where the possibility exists of erecting the
member in an inverted position.

8.7.7 All columns to have the mark painted on the outside face of the flange and to be
marked “North” or” East”. For spliced columns, column marks shall carry a level
suffix.

8.7.8 Gratings shall be tagged with a metal plate having raised letters so that the mark
shall be visible after galvanizing. This metal plate shall be seal welded to the
grating prior to galvanizing. Fabrication sub-contractor may submit alternate
proposal for marking galvanized members, subject to CONTRACTOR’s written
approval.

8.7.9 Hard stamps, punched or drilled marks shall only be permitted with
CONTRACTOR’s approval and in no case shall it be permitted on steels above
grade S355 or on cold formed components or on coated members.

9 PACKING, TRANSPORTATION AND STORAGE

9.1 GENERAL

9.1.1 Packing and shipping will be carried out in such a way that during transportation,
lifting and storage outside, no damage or loss of parts can occur. Particular

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attention shall be given to slinging methods to avoid damage to protective

treatments.

9.1.2 Packed items will have clear identification references concerning contents and
weights.

9.1.3 Bolts for field connections shall be shipped to the jobsite together with the steel
members they are intended to be used with.

9.1.4 Transportation will be done in logical sequence to prevent erection delay.

9.1.5 Prior to shipment, the fabrication sub-contractor shall transmit the shop drawings
in order to be able to identify steelwork members as they are delivered.

9.1.6 If any confusion is likely to arise in reception, sorting or distribution of the goods,
all parts shall have painted on them a further distinctive mark in addition to any
erection or transportation marks. Such additional marking shall consist of a
coloured band or other mark.

9.1.7 All identification marks shall be applied on at least two sides of each package.

9.1.8 All packing and transportation shall be in accordance with the approved packing
and marking procedure.

9.2 RECEIPT OF MATERIAL

9.2.1 Upon receipt and concurrent with unloading, the structural steel shall be inspected
insofar as possible for conformance to bills of loading and determination of damage
in transport.

9.2.2 Any evidence of nonconformity and/or damage shall be reported immediately to

allow proper measures to evaluate and/or rectify the situation.

9.2.3 Systematic unloading and segregation will assist CONTRACTOR’s Material

Department in checking the transportation and will help to avoid delays by early
discovery of missing material.

9.2.4 Columns and beams shall be laid out to facilitate identification and erection.

9.2.5 Smaller components, such as bracing, ladders, cantilevers, platforms, etc., shall
be segregated and stored clear of the main structural members.

10 ERECTION

10.1 ERECTION METHOD STATEMENT

The CONTRACTOR shall submit an erection method statement to COMPANY
for approval.
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The method statement shall describe the procedures to be used to safely erect
the steelwork and shall take into account technical requirements, available
access to the jobsite location and the need to coordinate the erection work with
other sub-contractors working in the vicinity.

10.2 ERECTION DRAWINGS

Marking plans, erection drawings, bolting lists, etc., are required at jobsite at least
one week before receipt of material.

10.2.1 Anchor bolt holes and baseplates

10.2.2 The location and orientation of already installed anchor bolts shall be checked
against the base plates of the main columns before such columns are lifted for
installation.

10.2.3 If they do not match, CONTRACTOR’s approval is required before the proposed
correction is executed.

10.2.4 Before setting of base plates, concrete surfaces shall be roughened and cleaned.
Shims to be installed for levelling the supported members. Tighten the anchor bolts
after supported members have been positioned, plumbed, levelled and aligned.
Shims shall be located at least 10 mm inward from the base plate edge to secure
grouting cover and prevent rust bleeding.

10.3 FIELD WELDING AND FLAME CUTTING

10.3.1 Field welding and flame cutting is only allowed after approval by COMPANY. Sub-
contractor shall take all necessary precautions for protection of other materials and
equipment.

10.3.2 Field welding shall be kept to the absolute minimum, especially when parts are
galvanized.

10.3.3 Welding of structural steel shall be done only with qualified welders and approved
welding procedure.

10.3.4 Test Samples

 Test samples of welder’s work shall be furnished to CONTRACTOR for
approval, when requested.
 Welding and flame-cutting procedure qualifications shall be carried out using
representative samples of materials to be used in the work.
 The tests shall include specimen weld details representative of the actual
construction, which shall be welded in a manner simulating the most
unfavourable conditions liable to occur in the particular fabrication.

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 After welding, the specimens shall be held at a temperature not less than 10oC
for a period not less than 72 hours and shall then be sectioned and examined
for cracks and other defects.

10.3.5 In welded structures, the welding foreman or inspector shall mark all connections,
to show welding details ahead of welding crews.

10.3.6 Field welding of structural and miscellaneous steel shall be performed at the
locations indicated on the drawings.

10.3.7 Welding shall be carried out only under the direction of an experienced and
competent supervisor. A record shall be kept to enable butt welds to be identified
with the welders responsible for the work. All welds shall be marked with the
responsible welder.

10.3.8 Butt welds, which are shown on drawings to have complete penetration, shall be
produced with the aid of backing material or shall have the root of the initial layer

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gouged out on the back before welding is started from that side and shall be so
welded as to secure sound metal and complete fusion.

10.3.9 Weld lengths called for on the shop drawings are the net effective lengths,
excluding the un-fused start and the crater.

10.3.10 Welding shall be carried out sheltered from rain or wind. Welding shall be
stopped when the temperature inside the welding station is 0oC or below.

10.3.11 Slag shall be removed and the weld shall be wire-brush cleaned.

10.3.12 When, during construction maintenance, cut-outs or repairs by flame have to be

made or surface area has to be prepared, grating shall be removed to a safe area
to avoid that molten zinc will attack stainless steel piping and/or equipment.

10.4 ASSEMBLY

10.4.1 The erection of the steelwork shall be carried out in accordance with the erection
method statement provided by the CONTRACTOR.

10.4.2 Stability of the steelwork shall be ensured at all times. Foundation bolts shall not
be used to secure un-guyed columns against overturning unless they have been
checked, by calculation, for this mode of use.

10.4.3 All temporary bracing and restraints shall be left in position until erection is
sufficiently advanced to allow its safe removal.

10.4.4 All temporary anchoring devices shall be made secure against unintentional
release.

10.4.5 Each part of the structure shall be aligned and levelled as soon as practicable after
it has been erected and final assembly shall be completed as soon as possible
thereafter.

10.4.6 Permanent connections shall not be made between components until a sufficient
portion of the structure has been aligned, levelled, plumbed and temporarily

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connected to ensure that components will not be displaced during subsequent

erection or alignment of other parts of the structure.

10.4.7 Before setting of baseplates, concrete surfaces shall be roughened and cleaned.
Shims shall be made of flat steel unless specified otherwise.

10.4.8 Unless specified otherwise, drifts may be used to align connections.

10.4.9 In case of misalignment of bolt holes the method of correction shall be subject to
approval by the COMPANY. Correction of misalignment by reaming or using a
hollow milling cutter is preferred; burning of holes shall not be permitted.

10.4.10 All steelwork shall be plumb and level. Thoroughly fasten brace and guy
structures permanently bolting, so as to keep the structural members plumb and
true during erection.

10.4.11 During erection, temporary bracing and guys shall be used to maintain structural
integrity.

10.4.12 At-least one daily contact should be made with local weather bureau, so as to
be forewarned for possible high winds.

10.4.13 Sufficient temporary wind bracing should be used overnight and during
weekends and holidays to prevent collapse by wind.

10.4.14 Subassemblies as indicated below (table 1) shall be made up at grade or

shipped assembled when practical, bearing in mind the possibility of damage to
assembled steelwork during shipment.
Table 1
Item Subassembly Comprises Erection Unit
Stairways Stringers, treads and Single flights
handrail sets
Miscellaneous operating Frame decking, supports Each platform
platforms and handrail sets
Circular platforms All structural components Each platform
(180o maximum)
Safety ladders Ladder and cage Single flights
Rigid building frame Columns and beams Single frame
Roof trusses Normally shop assembled Each truss
Handrails Posts, rails and toe-plate Section
Cage set Loose items strapped Section
together

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10.4.15 Access is forbidden for personnel not engaged in the erection of steelwork, until
the structure is finally bolted up and hand-rails and stair treads are installed.

10.4.16 Erection cranes shall be so positioned that booming up or down and “walking”
are kept to a minimum.

10.4.17 Auxiliary cranes, cherry pickers, trailers, etc., shall be used as required to feed
columns, beams, reassembled units, etc., for the erection crane.

10.4.18 The sequence of erection shall be as described in the erection method statement
with the general principle that members furthest from the crane are installed first,
or as dictated by safety requirements.

10.4.19 Normal procedure should be to plumb main columns and beams between
splices, before starting to dress the elevations of the structure with the secondary
members.

10.4.20 Temporary planking and installation of temporary protective railing for erection
purposes shall be executed by erection sub-contractor and in accordance with
safety regulations.

10.4.21 In order to increase accessibility, platform flooring and stairways shall be

installed as soon as practical.

10.4.22 The use of platforms and walkways as storage areas for material shall be
carefully controlled from the standpoint of safety, accessibility and allowable
design loads.

10.4.23 As soon as possible after plumbing the structure, erection with permanent bolts
and all connections shall be completed.

10.4.24 When using calibrated torque wrenches for tightening “bearing-type

connections”, calibration shall be checked and recorded, at least twice per shift, at
start of shift and immediately after mid shift break.

10.4.25 Fit-up clips shall be removed carefully to avoid tearing structural members and
all weld marks shall be ground smooth after which the coating in the area shall be
repaired.

10.5 TIGHTENING OF BOLTS

Torque requirements for tightening of bolts used in bearing-type
connections shall be as follows:
For M16 and M20 : 50 Nm.
For M22 and M24 : 100 Nm.
For M27> : 200 Nm.

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10.5.1 Anchor bolts shall be firmly tightened as soon as columns are set and grouted.
They shall be fully tightened after the first level has been plumbed.

10.6 TOLERANCE AND CORRECTIONS

10.6.1 Erection tolerances shall be in accordance with the limits stated in Appendix D of
EN 1090: Execution of steel structures and aluminium structures. Part 2: Technical
requirements for structures or AISC guidelines.

10.6.2 Correction of fabrication deviations, which involve flame cutting, heating, additional
holes, relocation of clips, etc., shall not be undertaken without approval of
CONTRACTOR.

10.6.3 Erection sub-contractor shall submit to CONTRACTOR a sketch in duplicate,

showing the deviation and the proposed method of correction. CONTRACTOR
shall indicate approval by signing both copies of the sketch. He shall return one
copy to supplier and retain the other for his files.

10.6.4 Where flame cutting is done it shall be mandatory to finish all surfaces smooth and
rounded with no corners or points of sharp curvature remaining as a possible
source of stress concentration.

10.7 SAFETY

10.7.1 Safety for erection of structural steelwork shall be in accordance with COMPANY
and regulatory requirements.

10.7.2 Scaffolding used for erection of structural steel shall be installed and inspected in
accordance with project and regulatory requirements by qualified personnel.

10.8 FIELD PAINTING

10.8.1 Galvanized surfaces shall not be painted. For repair to damaged areas refer to
project specification A-MTL-SPE-000-30003 “Specification for Surface preparation
and painting”.

10.8.2 Steel surfaces on which the shop coatings have been damaged shall be thoroughly
cleaned and shall be touched up with primer and painted, all in accordance with
project specification A-MTL-SPE-000-30003 “Specification for Surface preparation
and painting”.

11 FIELD INSPECTION
The CONTRACTOR reserves the right to inspect the erection of the structural steel
at any time to assure that the materials and workmanship are in accordance with
this specification and contract.

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12 QUALITY CONTROL

12.1 QUALITY SYSTEM

12.1.1 The purpose of this section is to assure that the fabrication and erection and
delivery of the structural steel is in agreement with the COMPANY requirements,
this specification and fabrication sub-contractor’s shop fabrication drawings and
that quality control procedures for structural material handling, storage and
erection are carried and documented out as prescribed herein.

12.1.2 CONTRACTOR shall submit his quality plan for fabrication and erection of
structural steel in accordance with ISO 9000, to COMPANY, before commencing
the steelwork. It shall include but not be limited to:
 An organisation chart
 The allocation of tasks and responsibilities during the various phase of
the works
 The procedures and methods to be applied including welding procedures
 The procedure for providing certificates for constituent products and
consumables
 The procedure for dealing with changes and modifications
 The procedure for dealing with non-conformities
 An inspection plan specific to the works
 Pro forma copies of execution records that will be used to document
inspection and compliance with specifications for the elements of the
works

12.2 MATERIAL

12.2.1 All structural steel items shall be accompanied by certificates in accordance with
this specification.

12.2.2 Bolts, nuts and washers shall be accompanied by documents as require by this
specification.

12.3 FABRICATION / RECEIPT / STORAGE

12.3.1 Drawings, shop fabrication, inspection reports, including the material certificates
and documents, shall be at site and checked against this specification and shop
fabrication drawings.

12.3.2 CONTRACTOR’s inspector shall inspect prefabricated structural steel deliveries

to detect any imperfections of damage resulting from fabrication handling or

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transportation. All shipment must be properly documented, photographed and

reported. Material receiving reports and, if required, overage, shortage and
damage reports made and issued immediately.

12.3.3 CONTRACTOR’s inspector shall assure that care is taken to prevent the steel
members from being damaged or soiled during storage and handling.

12.3.4 No welding of structural steel may be done without qualified welders and approved
welding procedure.

12.4 ERECTION
 The method used for erection of structural steel depends upon:
 The type and size of structure.
 The risks involved.
 Whether the structure is to be erected without interference with other
work or operations.
 Availability of lifting devices.
 Local conditions.

12.4.1 All tools, equipment and ropes used for erection shall be currently certified for the
purpose intended.

12.4.2 The CONTRACTOR shall submit to the COMPANY an erection plan, complete
with data on heavy lifts and shipping weights.

12.4.3 Approval of this erection plan by the COMPANY does not relieve the erection
Contractor from his full responsibility for the erection of the structure in a safe and
orderly manner.

12.4.4 CONTRACTOR shall submit an erection plan procedure for bolting and welding
procedures before commencing erection. Welders shall be qualified as per
applicable standard and shall be approved and accepted by COMPANY

12.4.5 Verticality, level and alignment shall be checked. Corrections and/or alterations
required as result of poor fit shall be reported and approved by the

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CONTRACTOR. Uncontrolled burning and welding is not permitted. Any

requirement for work of this nature has to be approved first by the CONTRACTOR.

12.4.6 All bolt connections shall be checked by erection sub-contractor to be sure that all
temporary erection bolts, etc., are removed and replaced by construction bolts.

12.4.7 After checking of connection, the erection drawing shall be marked to indicate
acceptance.

12.4.8 Any connection containing loose bolts will be inspected 100%.

12.4.9 Loose bolts will be brought to the attention of the CONTRACTOR and re-inspected
for compliance.

12.4.10 Checking of bolted connections shall be done with a calibrated impact wrench.

12.5 FINAL INSPECTION

12.5.1 Before the steel structure will be accepted for final inspection, the following
requirements shall be verified:
 All temporary provisions and temporary materials not required for access
for inspection have been removed.
 Quality records are available and have been approved and signed off by
all parties.

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