Structural Specifications

DIVISION 05 - METALS

Structural Specification

05000 GENERAL
05010 METAL MATERIALS
05050 METAL FASTENING
05120 STUCTURAL STEEL
 Structural Specifications

05000 GENERAL

A) SCOPE

1) This Part provides the specification for all necessary calculations, shop drawing, manufacture,
fabrication, erection and associated items for building frames and other similar steel work.

Also, this part specifies the requirements associated with all aspects of structural steel work including
materials, drawings, workmanship and protective treatment.

2) Related Sections and Parts are as follows

a) QCS 2014 Section 5 Concrete

b) QCS 2014 Section 16 Structural Steelworks

B) SUBMITTALS

1) Refer to submittals of every section of this division.

***End of Section 05000***

GENERAL 05000 - 1
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05010 METAL MATERIALS

A) GENERAL

1) SUMMARY

a) Section includes all types of metal material such as mild steel, and miscellaneous metals.

2) RELATED SECTIONS

a) QCS 2014 Section 1702 Material Types and Finishes

3) REFERENCES

All metals shall comply with the following British Standards or internationally recognized equivalents

BS 476 Fire tests on building materials and structures

BS 1245 Metal door frames (steel)

BS 1282 Guide to the choice, use and application of wood preservatives.

BS 1449 Steel plate, sheet and strip.

BS 1706 Electroplated coatings of nickel and chromium

BS 7036 Code of practice for provision and installation of safety devices for automatic power
operated pedestrian door systems

BS 7773 Code for practice for cleaning and preparation of metal surfaces

BS EN 288 Approval of welding procedures for metallic materials

BS EN 10142 Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming:
technical delivery conditions.

BS EN 10143 Continuously hot-dip metal coated steel sheet and strip –Tolerances on dimensions and
Shape

BS EN 10152 Electrolytic ally zinc coated cold rolled steel flat products –Technical delivery conditions

B) SUBMITTALS

1) Samples

a) The Contractor shall submit samples as follows:

i) Submit samples of all materials and finishes including the samples matching the appearance,
colour, texture, and other characteristics of each finish required.

ii) Finished samples of panels and major extrusions.

iii) Range samples showing the complete range of variation in colour,texture,and other characteristics
resulting from the manufacture, finishing, fabrication, delivery, assembly, installation, and cleaning
processes.

iv) Samples showing finishes over welds and over materials welded.

b) The size of all samples to be agreed with the Engineer or as noted in the contract documents.

c) The Contractor shall submit any pre-printed or prepared manufacturer’s performance data.
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2) SYSTEM DESCRIPTION

a) Materials and components used shall be as specified or be suitable equivalents as approved by the
Engineer.

b) Materials not specified are to be of the best quality and suitable for the purpose intended and as
approved by the Engineer.

c) All materials are to be free from any defect that may impair the strength, functioning, durability, or
appearance of the work of this Section or of adjacent construction.

3) METALS

a) It is the responsibility of the Contractor to select the alloy, degree of alloy control, homogeneity,
temper, metallurgical quality, degree of hardness or softness, mill tolerances, cutting tolerances and
flatness required to achieve the requirements of design, quality, and colour matching of finish set
forth in the Project Documentation.

b) Suitable low-friction separation materials shall be provided where metal materials are adjacent and
subject by design to relative movement against one another. Suitable low friction separation
materials are as follows:

i) teflon strip, 750 microns thick and teflon tape, 125 microns thick
ii) high-impact polystyrene
iii) other materials as approved by the Engineer.
iv) Low-friction material shall be impervious to moisture.

C) PRODUCTS

1) HOT–ROLLED STEEL SECTIONS

a) Hot-rolled steel sections shall comply with BS 4, Part 1, except equal and unequal angles which shall
comply with BS 4848, Part 4, and hollow steel sections which shall comply with BS 4848, Part 2.

b) Hot-rolled sections shall be made from steel to BS EN 10025 and unless otherwise specified all
sections shall be of Grade S275 minimum.

2) LIGHT GAUGE STRUCTURAL SECTIONS

a) Light gauge structural section shall comply with BS 449, Part 2 – Addendum No. 1.

3) STEEL PLATES

a) Steel plate shall comply with BS 4360.

4) BOLTS, SCREWS, NUTS and WASHERS

a) ISO metric black hexagonal bolts, screws and nuts shall comply with BS 4190 and BS 3692. ISO
metric countersunk head bolts, screws and hexagon nuts shall comply with BS 4933. Washers shall
comply with BS 4320.

5) HIGH STRENGTH FRICTION GRIP (HSFG) BOLTS

a) HSFG bolts and associated nuts and washers shall comply with BS4395, Parts 1 and 2 with bolt
grade 8.8.

6) ELECTRODES FOR MANUAL-ARC WELDING

a) Refer to Section 05050 - Welding

***End of Section 05010***

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05050 METAL FASTENING

A) GENERAL

1) SUMMARY

a) Section includes metal fastening systems such as anchors, bolts and welding

2) RELATED SECTIONS

a) QCS 2014 Section 16 Part 5 Welding

b) QCS 2014 Section 16 Part 6 Bolting
c) Section 05010 Metal Materials
d) Section 15051 Mechanical Specification - Welding

B) PRODUCTS

1) ANCHORS

a) METHODS OF FIXING

i) The Contractor shall submit for the approval of the Engineer samples of those fixing devices he
considers suitable for attaching and supporting cladding units, metal structure, etc. to in-situ
concrete, structural frame or concrete block substrates.

ii) In making his choice the following criteria shall be taken into account :
(A) The fixing devices shall be capable of withstanding the combination of direct bending, shear
and torsional stresses.

(B) The fixing devices shall be designed and fabricated so that they are able to withstand wind
pressure and suction equal to the basic wind pressure appropriate for the grade of exposure
and height above ground level of the individual units, taking into the higher wind pressures at
corners. To avoid errors on the site in the selection of fixings, they shall be capable of being
used at any place on the elevation of the building.

iii) The choice of anchor shall bear consideration to the nature of expansion within the supported
material due to temperature and humidity variations. The Contractor shall be entirely responsible
for the sufficiency of the fixing.

b) CHEMICAL FIXING

i) The Contractor shall provide adequate support for the element being fixed during the time of
curing indicated by manufacturer. When fixing the ambient temperature shall not exceed 30 deg.
C and the Relative Humidity shall not exceed 80% unless otherwise indicated by the
manufacturer's instruction.

c) CAST IN ANCHORS

i) Cast in anchors, channels, threaded tubes, etc., shall be of a construction allowing maximum
bond to concrete generally by means of fishtail 3-5mm plate, 100mm long.

ii) The cast in anchors shall be accurately positioned inside the formwork and secured by adequate
means preventing it from sliding or tilting from its final position during the pouring of concrete.

iii) Where special tying to reinforcing bar is required it shall be done in strict accordance to drawings
to full satisfaction of the Engineer.

d) PURPOSE DESIGN FIXING

i) The anchors shall be manufactured strictly in accordance to drawings or be substituted by an

equally efficient fixing for which the Contractor shall provide full working drawings with any
necessary explanation and structural calculations to the entire satisfaction of the Engineer and
written confirmation of approval.
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2) BOLTS

a) GENERAL

i) The fixing shall be made strictly in accordance with Manufacturer's instruction. The choice of
drilling technique and size of drill for the socket shall be adapted to the particular bolt size.

b) BOLTED CONNECTIONS

i) Holes in members over 10 mm thick shall be drilled and in members of 10 mm or less may be
punched, cleaned of burrs or rough edges and countersunk where required before assembly.

ii) All holes shall be the appropriate size for the type and diameter of bolt being used and shall not
be more than 2mm larger than the diameter of the bolt passing through them.

iii) Drift pins shall only be used to bring together the several parts of the structure and shall not
distort or enlarge the holes. The Engineer shall be informed where misalignment exceeds one
third of the hole diameter off center, and will either reject the work or order the holes reamed out.
Under no circumstance shall the holes be enlarged by thermal cutting, or shall the bolts be driven
into position.

iv) All bolts shall have steel washers minimum 2.4 mm thick between the part being turned and the
member being fixed. Tapered washers shall be fitted to the head and / or nut where the bearing
surface slopes more than 3 Deg. C. from a pane at right angles to the bolt areas. Care shall be
taken to ensure that the washers have the correct taper and are placed the right way round.

v) Bolts connecting metal-coated steel shall have the washers fitted under both the head and the
nut.

vi) All bolts shall show at least two turns of complete threads beyond the nut face. The threaded
portion of all bolts other than HSFG bolts shall terminate clear of any shear plane in the joints.

No bolted connection shall have less than two bolts through each member. In the case of double –
span purlins and rails, this condition may be waved with the approval of the Engineer.

c) GROUTING OF BOLT HOLES AND UNDERPINNING OF BASE PLATES

i) The grouting of bolt holes and the underpinning of base plates shall meet with the requirements
of ASTM C1107. Grouting material shall be cementitious, non-shrink, free flow grout.

ii) The minimum grout strength shall be 48 MPa at 28 days.

iii) Acceptable manufacturers are:

(A) BASF Chemical Co.

(B) Sika
(C) Hilti
(D) In case of unavailability of manufacturers or products listed above, refer to Engineer.

iv) Examination:

(A) Verify by examination that all concrete substrate and plate surfaces are acceptable for grout.

v) Preparation:

(A) Mechanically remove all unsound concrete to the limits indicated on the drawings. Remove
cement paste and laitance to expose sound aggregate.

(B) Clean surfaces of dirt, dust and debris. Clean rust from base plates and other metal surfaces
to be grouted to obtain satisfactory adhesion.

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(C) Maintain substrate in a saturated condition for 24 hours prior to grouting. Surface should be
saturated, surface dry (SSD) at time of grout installation.

(D) Formwork to be liquid tight, and per Manufacturer's recommendations.

vi) Mixing:

(A) Comply with Manufacturer's recommendations for mixing procedures.

vii) Installation:

(A) Place grout mixture into prepared areas from one side to the other, rapidly and continuously,
to reduce air entrapment. Avoid placing grout from opposite sides.

(B) Protect foundation and base plate from excessive heat, cold or wind.

(C) Cut back or form exposed shoulders when grout reaches initial set.

viii) Curing:

(A) Wet cure exposed shoulders for 72 hours, followed by one coat of membrane curing
compound.

d) CONNECTIONS

i) The Contractor shall undertake all calculations and detail all connections in accordance with the
appropriate British Standards from the information given in the specification and as shown on the
drawings. Shop connection may be bolted, riveted or welded but site connections shall be bolted.

ii) Bolts accompanying with BS 3692 or 4190 shall be of strength grade 8.8 and washers used with
such bolts shall be tapered or flat as appropriate to ensure full bearing for the nuts and the bolt
heads.

iii) All bolts in any one connection shall be of the same diameter and all bolts used in Site shall be of
the same strength grade.

iv) High strength friction grip bolts shall be the grade shown on the detailed or shop drawings. High
strength friction grip bolts used in site connections shall have load indicating heads and shall be
used in accordance with the Manufacturer’s recommendations.

e) HSFG BOLTED CONNECTIONS

i) HSFG Bolts shall be used in accordance with the relevant part of BS 7064.

ii) The contact surfaces of connections shall be free from paint, grease, oil or other material which
would reduce the frictional properties of the joint. Where necessary to prevent the nuts seizing on
the bolts, liquid high pressure lubricant may be applied only the outstanding threads after the
bolts have been inserted through the steel work.

iii) HSFG assemblies shall comply with section 16 part 6 QCS 2014

iv) HSFG Bolt/nut/washer combinations shall comply with BS 4395 Parts 1 or 2, as appropriate.

v) The use of friction grip bolts shall comply with BS 4604. Part 1 or 2.

3) WELDING

a) All welding shall be carried out in accordance with Section 16 Part 5 QCS 2014 or as amended by
this Specification in such a manner as to minimize distortion and locked-up stresses.

i) Contractor is responsible for selection of specific materials and procedures except as specifically
noted in contract documents.

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ii) Connections have varying levels of restraint and thus necessary steps shall be taken by
Contractor to control or accommodate the restraint.

iii) Contractor shall submit for approval welding procedure specification (WPS) prior to start of any
welding works and procedure qualification record (PQR) in conformance with AWS D1.1(steel
structures), ASME IX (piping and pressure vessels) and BS EN 288 part 4 (Aluminium), BS EN
ISO 1101-8 (Iron), and BS EN ISO 15609 (Metallic materials) as appropriate.

iv) In addition to the Welding Procedure Specifications, submit fabrication and erection procedures
where needed to control shrinkage, fabrication tolerances, or to insure proper inspection.

v) When selecting materials and procedures, consideration shall be given to the need for materials
and procedures in excess of code requirements.

vi) The need for pre-heat and other procedures are to be based on the actual chemistry and
mechanical properties and not solely on the grade for which the steel was certified.

vii) Weld variables shall be consistent with the recommendations of the electrode manufacturer.

viii) Approved Welding Procedure Specifications (WPS) shall be readily available to all welders,
inspectors, and supervisors.

b) Welders shall be tested to meet the requirements of BS EN 287 Part 1 but, in the case of welders
engaged on fillet welding only, BS 4872 Part 1 is an acceptable alternative. As an alternative, when
permitted by the Employer, welders may be tested to meet the requirements of the American Society
of Mechanical Engineers, ASME IX, or the American Welding Society, AWS D1.1.

c) Welder testing shall be witnessed and certificates endorsed by an independent Inspection Authority.
The certification shall remain valid providing it complies with the conditions for re-approval of
certification specified in BS EN 287 Part 1.

d) The Contractor shall notify the Inspector in sufficient time prior to fabrication or erection work to allow
testing and inspection without delaying the work. Shop welds will be inspected in the shop before the
work is painted or shipped.

e) As a minimum the inspector shall make all tests and inspections as required by the 1994 Uniform
Building Code. Inspector will make all the tests and inspections indicated in the Construction
Documents.

f) The Inspector shall make all verification tests and inspections as required by AWS D1.1 "Structural
Welding Code" or section 16 part 5 QCS 2014

g) Do not reduce testing frequency unless permission is obtained from the Engineer.

h) Inspector shall be present during all welding operations.

i) Verify that welders are certified.

j) Check materials, equipment and procedures. Verify meters on welding equipment are functioning
and are accurate.

k) Visual Inspection:

i) Visually inspect all welds.

ii) Visual inspection of multi-pass welds to be continuous.

iii) Visually inspect welds to Group [4 and 5] sections of at least [72] hours after completion of
welding for the presence of cracks.

l) Test Methods:
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i) Butt welds will be tested using ultrasonic or radio-graphic test methods.

ii) Use magnetic partial test methods for fillet welds and to supplement the testing requirements for
butt welds.

iii) At inspector's option dye penetration testing, and resistance testing methods may be used in
place of or to supplement magnetic particle testing.

iv) For radio-graphic a double film technique will be used. One copy of each film will be sent to the
Engineer, the other will be retained by the Inspector.

v) In addition to the non-destructive testing specified other non-destructive test methods recognized
by AWS D1.1 may be used at the Engineers discretion and the results can be used to reject work
under this contract.

m) Frequency of non-destructive examination is to be as follows:

i) Full Penetration Butt Welds: 100 percent.

ii) Test [20 percent] of total length of all welds joining web plates to flanges.

iii) Fillet and other welds not otherwise addressed - a minimum of 10 percent.

iv) Selection of welds to be examined: Where there is a requirement for less than 100%
examination the method of selection of welds to be examined is to be agreed with the Engineer
before commencement of the work. If the Engineer does not provide more specific criteria
inspectors will select the welds to be tested. The inspectors will choose specific weld so as to
obtain results that are representative of the conditions in the structure. In addition, inspectors will
emphasize those locations that experience has shown are more likely to have problems.

v) On five percent of the full penetration butt welds as chosen by the inspector/engineer, after
removing, run-off tabs, grind the end of the weld sufficiently to allow determination of number and
sizes of weld passes.

n) Testing of Base Metal: These provisions are in addition to other applicable requirements.

i) The edges of material to be welded will be ultrasonically examined for evidence of lamination,
inclusions or other discontinuities

ii) Ultrasonically test column flanges and webs at the location of all moment connections and brace
connections. Test for a distance 3 inches around the location to be welded. The test procedure
and acceptance criteria is defined by ASTM A898-91, “Standard Specification for Straight Beam
Ultrasonic Examination of Rolled Steel Structural Shapes” Level I.

iii) Base metal thicker than [1-1/2] inches, when subjected to through-thickness weld shrinkage
strains, shall be ultrasonically inspected for discontinuities behind and within a distance of 3
inches of such welds after joint completion. Any material discontinuities shall be accepted or
rejected on the basis of the defect rating in accordance with flaw severity, Class B criteria in
Table 8.2 in AWS D1.1.

o) Where inspection reveals unacceptable defects:

i) The extent of inspection will be increased as much as necessary to assure that the full extent of
the defects in a joint has been found and to assure that the same defects are not present
elsewhere.

ii) As a minimum, examine two additional joints in the group represented by the joint. If the non-
destructive examination of the two additional joints reveals unacceptable defects, examine each
joint in the group.

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p) Take samples of all welding consumables and store in sealed containers.

q) Make systematic record of all welds, including:

i) Location and type of weld.

ii) Identification marks of welders.

iii) List of defective welds.

iv) Manner of correction of defects.

r) The Inspector will maintain a daily record of the work that has been inspected and its disposition.
One copy of each of the report will be submitted to the Employer on a weekly basis. Test reports will
be made on the form suggested in the AWS D1.1 "Structural Welding Code."

s) The electrodes and fluxes to be used shall be chosen so that the mechanical properties of the
deposited weld material and parent material are comparable. In the case of construction which
comprises a mixture of mild and special steels, the deposited weld material a mixture of mild and
special steels, and deposited weld material shall comply with the test requirements of the higher
strength material.

t) All filler materials, electrodes, welding rods shall conform to AWS A5.1 or AWS A5.5 or ASME SEC.2
PART C. Electrode shall be used for arc welding with a min. tensile strength of 560 MPa. Use low
hydrogen electrodes wherever applicable.

u) Welds shall only be located where shown on the drawings and shall not be used for temporary
attachment or repair of faulty plates without approval.

v) The lengths of welds shall be calculated excluding end craters. Track welds shall not be less than 50
mm long except on tubes.

w) Run on and run off plates shall be used in the making of all butt welds and of all welds by automatic
processes to ensure a full throat thickness at the ends as follows:

i) The material for the plates shall be identical to the material being welded.

ii) The plates shall be prepared in the same manner as the parts being joined.

iii) After completion of the weld the plates shall be removed and the surfaces to which they were
attached shall be ground smooth.

iv) The plates shall be identified and retained for inspection if required.

***End of Section 05050***

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05120 STRUCTURAL STEEL

A) GENERAL

1) SUMMARY

a) Section includes steel framing members.

2) RELATED SECTIONS

a) Section 05010 Metal Materials

b) Section 05050 Metal Fastening

C) REFERENCES

1) All steel work including connections and other details not given in the Contract Documentation shall be
designed and fabricated to comply with BS449, Part 2 or BS 5950 or AISC.

AISC Load and Resistance Factor (LRFD) Specification for Structural Steel Buildings.

AISC Code of Standard Practice for Structural Steel Buildings and Bridges.

AISC Seismic Provisions for Structural Steel Buildings.

ASTM A36 Carbon Structural Steel. (ASTM A36M)

ASTM A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless.

ASTM A123 Zinc (Hot Dipped Galvanized) Coatings on Iron and Steel Products.

ASTM A153 Zinc Coating (Hot Dip) on Iron and Steel Hardware.

ASTM A242 High-Strength Low-Alloy Structural Steel. (ASTM A242M)

ASTM A307 Carbon Steel Bolts and Studs, 60 ksi Tensile Strength.

ASTM A325 Structural Bolts, Steel, Heat-Treated, 120/105 ksi Minimum Tensile Strength.

ASTM A449 Tempered Steel Bolts and Studs.

ASTM A490 Heat-Treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength.

ASTM A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and
Shapes.

ASTM A501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.

ASTM A514 High-Yield Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding.
(ASTM A514M)

ASTM A529 High-Strength Carbon-Manganese Steel of Structural Quality. (ASTM A529M)

ASTM A563 Carbon and Alloy Steel Nuts.

ASTM A568 Steel, Sheet, Carbon and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled Sheet,
General Requirements for. (ASTM A568M)

ASTM A572 High-Strength, Low-Alloy Columbium-Vanadium Structural Steel.( ASTM A572M)

AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination.

AWS D1.1 Structural Welding Code - Steel.

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BS 5950 Part 1 - 2000; Structural use of steel work in building; Code of Practice for design -
Rolled and welded sections.

FM (Factory Mutual) - Roof Assembly Classifications.

RCSC (Research Council on Structural Connections) - Specification for Structural Joints Using ASTM
A325 or A490 Bolts, LRFD or ASD.

SIS 055900 Swedish Standard

ISO 8501-1 International Organization for Standardization

UL (Underwriters Laboratory, Inc.) - Fire Resistance Directory.

WH (Warnock Hersey) - Certification Listings.

D) TOLERANCES

Location Permissible deviation mm

Position of first erected column ± 10

Space between - at Floor Level ± 15

- at Soffit Level ± 15

Overall length and width of building plan (up to 40m) ± 20

Plumb of columns - up to 3m ±8
- up to 7 m ± 10

Level of base of first erected column ±5

Level of beams - Flatness ± 10

- Variation in datum ± 20

Difference in level of ends of a beam ± 10

E) SUBMITTALS

1) SUBMISSION BEFORE FABRICATION

a) Steel Design Drawings: Prepared under the supervision of a professional Engineer, registered with
local body where project is to be constructed and acceptable to the Engineer, to perform design.

b) Engineering Calculations:

i) Include structural computations, material properties, and other information needed for structural
analysis as noted on the Drawings and related Specifications that has been signed and
sealed/stamped by the structural engineer who was responsible for their preparation.

ii) Calculation and steel design drawings to be submitted simultaneously.

c) The Contractor shall submit to the Engineer four (4) copies of each of the following after approval of
the steel design drawings:

i) Plans, drawings, sketches, connection details, material lists, forces, moments and calculations in
accordance with Clause under “Shop Drawings and Marking of Steel Works”.

ii) Details of proposed source of supply of steel work and dates of rolling

iii) Details of proposed program, sequence and methods of fabrication

iv) Details of proposed quality control for all shop work including welding
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v) Details of proposed program and method of transporting steel work to the Site

vi) Details of proposed program, sequence and method of erection including details of
Constructional Plant

vii) If high strength friction grip bolts are proposed, details of the manufacturer’s recommendations
regarding their use

viii) Details of materials and methods proposed to comply with the specified requirements for
corrosion protection, both in the shop drawings and, if appropriate, on Site after erection

ix) Descriptions and samples of all proprietary products, which the Contractor proposes to use in the
Permanent Works

b) Prior to start of fabrication work, contractor shall submit WPS according to ASME SEC. IX of
Engineer's review and approval. Necessary tests are to be conducted to established the WPS
and contractor is to maintain PQR.

2) SUBMISSION DURING FABRICATION

a) The Contractor shall submit to the Engineer four (4) copies of each of the following:
i) Mechanical test certificates and chemical analysis for all steel, including connectors, to be used
in the Permanent Works before such steel is incorporated.

ii) Welder’s certificates current at the date of fabrication for the appropriate classes of welding
before such welders are employed in the fabrication;

iii) Results of the agreed quality controls applied to the welded fabrication work;

iv) Results of the measurement of dry film thickness of shop applied protective paint systems.

A) SHOP DRAWINGS AND MARKING OF STEELWORK

1) The Contractor shall submit to the Engineer four (4) copies of setting out plans, shop drawings,
connection details, material lists and calculation sheets confirming that the structural steel work
connections will withstand the imposed forces and moments and shall make amendments to such plans,
drawings, details, lists and calculations as may be required by the Engineer.

2) On receipt of the Engineer’s agreement to such plans, drawings and lists, the Contractor shall submit a
further four copies of each to the Engineer. Fabrication shall not be started until the Engineer has agreed
to the relevant plans, drawings, details, lists and calculations, and once such agreement has been given,
no alterations shall be made to such plans, drawings, details, lists and calculations without the further
agreement of the Engineer. The Contractor shall submit all drawings and documents in a sequence and
at times compatible with the programme of work.

3) The design shall be in accordance with BS 449 Part 2 and other relevant British Standards.

4) The Contractor shall take all necessary site dimensions to ensure that the correct detailing, fabrication
and erection is carried out.

5) The agreement of the Engineer as described in this Clause shall not relieve the Contractor of his
responsibility for the sufficiency of the calculations, drawings, etc. or for the correct fabrication, assembly
and erection of the Permanent Works.

6) Before dispatch from the workshop, all steel work shall be clearly and indelibly marked to indicate its
position and direction in the Permanent Works, the grade of steel used for fabrication and the weight of
each piece if this exceeds one tonne. Such markings shall correspond with those shown on the shop
drawings.

7) On completion of steel work erection, the Contractor shall supply to the Engineer two reproducible
transparencies of all shop drawings.

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B) FABRICATION TOLERANCES

1) Fabricated members shall comply with the dimensions and shapes shown on the Drawings and the
accepted shop detail drawings within the tolerances set out below.
a) Length : plus or minus 2.0 mm.

b) Width and Depth : plus or minus 3.0mm

c) Straightness : A member shall not deviate from the straight line joining any two corresponding points
on the ends of the member by more than one thousandth part of the length.

d) Machined End Faces : No part of any machined end face of a member other than a column shall
deviate from a plane at right angles to the axis of the member by more than 0.5 mm. No part of the
machined bearing face of a column shall deviate from a plane at right angles to the axis of the
column by more than 0.25mm and 90 per cent of the bearing area shall have full contract uniformly
distributed over the whole of the whole of the area and substantially symmetrical about the major and
minor axes.

e) Built – Up Members :
i) The center line of a web shall not deviate by more than 6.0 mm from the plane
ii) For D/t less than 150, the least panel dimension divided by 100.
iii) For D/t greater than 150, the least panel dimension divided by 80, where D is the depth of the
web and t is the thickness.
(A) A flange shall not deviate from the plane passing through the center line of the outer surface
and at right angles to the plane of the web by more than 3.0 mm or the flange width divided
by 200 whichever is the greater.

C) INSPECTION AND RELEASE FOR DELIVERY OR SHIPMENT TO SITE

1) The Contractor shall give the Engineer reasonable notice in writing of the date on and the workshop or
place at which the steel work will be ready for inspection and testing, as provided in the Contract, and the
Engineer shall thereupon, at his discretion, notify the Contractor of his intention either to release such
steel work for delivery or shipment to the Site on receipt of works test certificates or of his intentions to
inspect and test such steel work. In the latter event the Engineer will, on giving twenty four (24) hours
notice in writing to the Contractor, attend at the workshop or place so named within ten (10) days of the
date by which the Contractor has stated in his notice that the said steel work will be ready for inspection
and testing.

2) Whether at the workshop or place of the Contractor or of any of his Sub-Contractors, the Contractor shall
provide such labour, supervision, materials, electricity, fuel, water, stores, apparatus, instruments or other
things required to carry out efficiently inspection and testing of the steel work, in accordance with the
Contract, and shall give facilities to the Engineer to accomplish such inspection and testing.

3) At the satisfactory completion of such inspection and testing, the Engineer shall issue to the Contractor a
notification releasing the steel work for delivery or shipment to the Site. No steel work shall be delivered
or shipped to the site until the Contractor has obtained from the Engineer his notice releasing such steel
work for delivery or shipment.

D) HANDLING, DELIVERY OR SHIPMENT TO SITE AND STORAGE AT SITE

1) The precautions to be taken when handling, transporting and storing steelwork shall include:

a) All sire ropes and chain slings used for hoisting and securing loads shall be covered to prevent
scoring, chaffing and other damage.

b) Softwood timber bearers with a sufficient contact area to prevent crushing shall be provided at all
stages of transporting and storage. Bearers shall be level and sufficient in number to prevent
distortion of members. Beams used to support steel work stored externally shall be sufficiently high
to ensure that the lowest parts of the stored members are above and clear of the rainwater splash
zone and that from passing vehicles.

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c) Special consideration shall be given to the arrangements of bearers, if articulated vehicles which
allow differential movement of bearers are used to transport steel work. Bolster wagons shall be used
if long members are transported by rail.

d) Vertical timber packings shall be used to separate members when required and to prevent chaffing.
The methods used for securing members during transportation shall ensure that steel work is not
damaged by the use of unprotected chains or other equipment used to secure loads in transit.

e) Steel members shall preferably be stacked in single layers. Where conditions require stacks or more
than one layer, softwood packings shall be used between layers.

f) Members shall be stacked in such a manner as to permit free drainage of rainwater from the surfaces
and to avoid ponding. If covers are provided to stored steel work, timber bearers or other form of
support which is acceptable to the Engineer shall be used to ensure that covers are not in contact
with steel surfaces. The arrangements for ventilation under the covers to minimize condensation
shall be acceptable to the Engineer.
g) Precautions shall be taken at all stages to prevent steel work being contaminated by oil, cement, soil,
chemicals or other deleterious agents. Should any contamination occur, the contaminating agent
shall be removed immediately by swabbing or brushing and the surfaces well washed with clean
water.

h) Steel work shall be loaded or unloaded by hoisting equipment. It shall not be moved by sliding or
skidding. Small components without packing shall be handled singly and shall not be thrown on or off
vehicles or at any other time. They shall be stored on pallets and precautions taken to prevent
chaffing.

E) LOAD TESTING AND CERTIFICATION

1) Any lifting and runway beams incorporated into the structure shall be installed and tested in accordance
with the requirements of BS 2853 – Design and Testing of Steel Overhead Runway Beams and Traveling
Trolleys

2) The Contractor shall submit to the Engineer four (4) copies in English of each Test Certificate with all test
readings. The test certificate shall state the conditions under which each test was carried out.

F) CERTIFICATES AND TESTING

1) When requested by the Engineer, the Contractor shall submit for approval copies of Certificates of Origin
and Mill Test Analysis Certificates for the actual steel sections being supplied. In addition, the Engineer
may require samples of steel sections, machined as necessary, to be submitted to an approved
independent testing laboratory for analysis and tests.

G) BRANDING / MARKING

1) All steel delivered to site shall be branded / marked in accordance with the relevant Standard whether
received from the mill or stock.

H) SHIPPING AND PROTECTION

1) Before shipment from factory, metal surfaces requiring protection shall be given a coating to protect the
metal during construction. In areas where appearance of the finish on metal items is important, a coating
of approved lacquer shall be applied.

2) The coating shall be applied in the manufacturer’s plant to the exposed surfaces of all metal components
subject to staining from alkaline mortar and plaster abrasion and other construction abuses. Before
application of lacquer, the manufacturer shall remove all fabrication compounds moisture dirt,
accumulations and other foreign materials to ensure proper lacquer adhesion.

3) Upon completion, the Contractor shall clean all metal work as required by removing protective tape or
other coating using mild soap or detergents and clear petroleum spirits.

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 Structural Specifications

I) QUALITY ASSURANCE

1) The acceptance of all assembled and/or welded work shall depend on correct dimensions, alignment and
absence of distortion.

2) All unacceptable members shall be removed and replaced at the expense of the Contractor

J) WORKMANSHIP

1) Workmanship shall be of the best quality in metal work.

2) All holes shall be drilled except where approval has been obtained for them to be punched.

3) The edges and ends of all plates and sections shall be accurately finished by shearing, cropping,
planning, sawing or milling.

4) Sheared edges will only be acceptable for high yield steel if not less than 3mm of the material of the
sheared edges is removed by machining.

5) Where sheared or cropped edges are acceptable for mild steel they shall be dressed to a neat
workmanlike finish and be free from distortion.

6) All sheared edges shall be planed.

7) For mild steel and for high yield steel up to 13mm thick, machine flame cutting will be acceptable.

8) For high yield steel over 13mm thick the edges produced by machine flame cutting will not only be
acceptable:
a)The flame-cut edge is subsequently incorporated in a weld;
b) The Contractor can demonstrate that the flame cutting procedure does not result in the hardening of
the cut surface above 35 Vickers Diamond Hardness.

9) Structural steel work will be subjected to inspection by the Engineer at all stages of fabrication and
erection, and access to the works for this purpose is to be granted. The Engineer is to be informed
when material is ready for inspection. Copies of mill certificates will be accepted as a guarantee of the
steel.

10) Construction working details are to be submitted to the Engineer for approval before the work on
fabrication or erection is commenced.

11) Bolt holes in hollow sections shall be sealed to prevent the ingress of moisture.

12) All finished members shall be free from twist, true to profile and straight or truly curved.

13) Base plates in excess of 0.50 m2 in area shall have 50 mm diameter air holes to facilitate grouting after
erection of a column.

14) Each primary member (columns beams and rafters) shall be fabricated from one continuous steel
section. Butt-welding of short steel lengths of Section to achieve the required overall steel member length
will not be permitted.

15) All steelwork members shall be fitted with welded earth lugs to facilitate earthing of the superstructure.

K) EXECUTION

1) CUTTING

a) Cutting shall be done in a manner to prevent distortion. The use of a cutting torch is permissible if the
member is not carrying substantial stresses during the operation. Gas cut edges which will be subject
to substantial tensile stress shall be cut by a mechanically guided torch or, if hand cut, shall be
carefully examined and any nicks removed.

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 Structural Specifications

b) All cut members shall have barbs removed and edges smoothed. Column shaft ends shall be milled
flat.

2) WELDING

a) Refer to Section 05050.B.3 : WELDING

3) PROTECTION AGAINST CORROSION

a) The Contractor will be responsible for the whole of the surface preparation scheme as detailed in this
specification. The materials and workmanship shall be in accordance with the recommendations of
ASTM A36 Part 1. The standard of surface preparation required shall be ASTM B177 Second Quality
Finish. The protection system is then to be applied as stated in Division 9 of this Specification.

b) If the Contractor wishes to propose an alternative painting system for the works he must demonstrate
that the overall performance of his proposed system will be equal to or better than that of the
specified system. The alternative system shall only be adopted on the written instruction of the
Engineer.

4) SURFACE PREPARATION

a) Surface preparation shall be in accordance with SIS-05-5900-1967/ISO-8501-1-1988.

b) Mill scale, rust, rust scale, etc. shall be fully removed by Grit blast cleaning to Sa 2 ½ or equivalent
as per SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988

c) Grit Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or in conditions where the humidity exceeds 85%.

d) The first coat of primer must be applied on dry surface immediately and in any case within 4 hrs
of cleaning of surface.

e) Blasting shall in general be avoided during unfavorable weather conditions.

5) PAINTING APPLICATION

a) To avoid any contamination of prepared surfaces, the priming coat shall be applied as soon as
possible after the preparation, and in any case within four hours.

b) Use a painting system for corrosivity category C5-M according to EN ISO 12944-5:1998. Total dry
film thickness 3 coats and expected durability "High"
i) min. 50 µm - max. 100 µm for primer coat (2 pack epoxy)

ii) min. 100 µm - max - 125 µm for intermediate coat (2 pack epoxy) and

iii) min. 50 µm - max. 100 µm for finish coat (2 pack epoxy)

c) The dry film thickness of the coatings will be measured by magnetic-type gauges in accordance with
Steel Structures Painting Council, specification SSPC-PA2. At the option of the engineer, the
adhesion of the coat will be measured in accordance with ASTM D 4541, min. 2.5 MPa. Locations for
adhesion tests shall be randomly selected. Test locations shall be in areas of least visibility in the
completed structure and shall be touched up in an approved manner after completion of the test.
When satisfactory test results are not obtained, additional adhesion tests shall be taken to determine
the area of insufficient adhesion.

d) All primed and undercoated surfaces shall be cleaned and dried before being painted with a
subsequent coat. Each coat of paint shall be finished to an even consistency and constant tint, free
from runs, blotches, deep brush marks and similar defects. All surfaces shall be completely covered
by each coat.

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e) The exposed parts of all bolts, nuts and washers, including those made in-situ, shall be given the full
painting treatment.

f) The mating surfaces of steel work joints shall be given at least one coat of priming paint and dried
before being bolted or riveted together, except when H.S.F.G. connections are permitted where the
contact faces shall be unpainted.

g) Brushes cleaned in solvent shall be thoroughly washed and dried before use.

h) Care shall be taken to avoid the contamination of 'non-painted' items with paint.

i) Any mixing or thinning of paint is strictly prohibited without the prior agreement of both the paint
manufacturer and the Engineer.

j) The normal method of paint application shall be by brush or roller. If the Contractor can satisfy the
Engineer and the paint manufacturer that a satisfactory job can be produced using airless spraying
equipment in accordance with the paint manufacturer's recommendations, then this shall be
permitted for shop painting, but not normally for site painting

a) Touch-up - After erection of all equipment and other items is complete and all fasteners are tightened
as specified. Thoroughly clean to remove all scale, rust, loose paint, salt, oil, grease and dirt. Paint
coats to be touched-up where necessary to a standard equal to the specified finish quality and
thickness. This process may require several coats of paint applied consistent with applicable
specified painting standards.

6) ERECTION

a) The erection work shall be under the direct control of an experienced erection supervisor.

b) Prior to delivery to site each separate item of steel work shall be legibly marked to matt black paint, in
accordance with an approved marking diagram, to facilitate identification and erection.

c) When erecting on or over concrete or other floor, care shall be taken to prevent damage to the floors
through careless handling of sections, bolts or spanners. Protection approved by the Engineer shall
be provided where it is necessary to run erection cranes and plant on the floors.

d) The hoisting of sections which have been painted is to be carried out using slings and timber or
rubber packs to minimize damage. Chains shall not be used.

e) During erection the work shall be securely bolted or otherwise fastened and if necessary temporarily
braced to make adequate provision for all erection stresses and conditions including those due to
erection equipment and its operation.

f) Column base plates shall be raised or lowered to correct level using sawn stainless steel packs or
wedges not larger than necessary for the purpose. The Engineer shall be informed where the space
between base plates and foundation is less than 10 mm or more than 60mm.

g) The Engineer shall be informed of any defects due to detailing in or fabrication errors and no
remedial work shall commence until the method of rectification has been approved.

h) The steel sliding surfaces of movement joints shall be coated with molybdenum disulphide grease
before connection and care shall be taken to ensure that bolts are in the centre slotted holes after
erection of the structure.

i) Members shall not be permanently connected until sufficient of the structure has been aligned,
leveled, plumbed and temporarily connected to ensure that they will not be displaced during the
erection and alignment of the remainder of the structure.

j) When HSFG bolts are used the method of identifying fully tightened connections (eg, a color spot of
paint) shall be agreed with the Engineer before erection commences. Tightening which complies
with BS 4604 Part 1, may be by the torque control method, partturn method, or with load indicating

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 Structural Specifications

devices used in accordance with the manufacturer's recommendations. Torque spanners and other
devices shall have a calibration check at least once per shift, and shall be re-calibrated where
necessary in accordance with BS 4604. If, after complete tightening, a bolt or nut has to be
slackened off, the whole bolt assembly is to be disposed of.

k) All necessary ladders, scaffolds or other suitable access shall be provided to enable the Engineer to
inspect the connections.

L) FIRE PROTECTION

1) PROTECTIVE TREATMENT MATERIALS

a) Metallic Blast Cleaning Abrasives
Chilled iron grit shall be in accordance with BS 7079 Part E2, and cast steel grit shall be in
accordance with BS 7079 Part E3.

b) Surface Coatings
Paint materials and other coatings supplied shall be in accordance with the appropriate British
Standard or European Standard for Materials.

c) Sherardized Coatings
Sherardized coatings shall be in accordance with BS 4921.

d) Galvanized Materials
The composition of Zinc in galvanizing baths shall be in accordance with BS 729.

e) Steel Protection System

Refer to General Notes.

***End of Section 05120***

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