a subsidiary of Eldorado Gold Corporation

Kisladag Capital Projects

KIŞLADAĞ, UŞAK, TÜRKiYE

STEEL MANUFACTURING & ERECTION

Technical Specification

Rev. Revision Date Created By. Checked By. Approved By. Description

C April, 2014 V. Yilmaz B. Akyüz M. Stice Updated Standards

B November 2013 V. Yilmaz B. Akyüz M. Stice General Update
A March,2013 V.Yilmaz T.Özenç J.Dircks General Update
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1 GENERAL

1.1 SCOPE OF WORK

This work shall consist of the necessary steel manufacturing and erection for all steel designed
structures.

1.2 APPLICABLE PUBLICATIONS

The latest editions of the following publications of the issues listed below but referred to thereafter
by basic designation only, form a part of this specification to the extent indicated by the references
there to:

TURKISH STANTARDS INSTITUTE (TSE) PUBLICATIONS

TS EN ISO 9606-1
TS EN ISO 3452-1
TS EN 1090
TS EN ISO 14732
TS EN ISO 17636-1
TS EN ISO 9013
TS EN ISO 8503
TS EN ISO 8501
TS EN ISO 5817
TS EN ISO 17640
TS EN ISO 17638
TS EN ISO 17637
TS EN ISO 15614-1
TS EN ISO 14713
TS EN ISO 1461
TS EN ISO 13920
TS EN ISO 12944
TS EN ISO 15607
TS EN 10305-5
TS EN 10305-3
TS EN 10204
TS EN 10160
TS EN 10056-2
TS EN 10051
TS EN 10048
TS EN 10034
TS EN 10028-2
TS EN 10025-2
TS 7227 EN 12584
TS 1980 EN 22768-1

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1.3 FABRICATION (SHOP) DRAWINGS

The fabrication (shop) drawings shall be submitted to Contractor by the Owner. Contractor will
review all the fabrication drawings and would present missing elements necessary revisions due to
miss typing and possible errors on connections.

1.4 REQUIREMENTS:

1.4.1 The European Standard TS EN 1090 specifies requirements for conformity assessment of
performance characteristics for structural steel and aluminium components as well as for
kits placed on the market as construction products.
1.4.2 Constituent products for steel components shall be in accordance with the European
Standards referred to in the relevant Clauses of TS EN 1090-2.

2 MATERIALS

2.1 SHEETS AND SECTIONS

2.1.1 Steel plates, sections, bars and hollow sections for structural steelwork purposes shall
comply with:

• Steels according to delivery standard TS EN 10025-2: S235JR, S235J0, S235J2+M,

S235J2+N, S355JR, S355J0, S355J2+M, S355J2 +N
• Steels according to delivery standard TS EN 10028-2: P235GH, P265GH, 16Mo3,
13CrMo4-5, 10CrMo9-10
• Fine-grained structural steels suitable for welding according to delivery standard TS EN
10025-3 or TS EN 10025-6: S355N, S460N, S690QL
• Hollow sections according to delivery standard TS EN 10305-3 and TS EN 10305-5.

2.1.2 And shall be to the grade specified on the drawings.

2.2 MANUFACTURER’S CERTIFICATES, SAMPLES AND TESTING

2.2.1 The Contractor, when requested by the Owner representative, shall provide certificates
from the manufacturer to confirm that the chemical composition and the mechanical
properties of the steel are in accordance with the appropriate Turkish Standards and/or EU
standards as mentioned above. If required by the Owner representative, facilities shall be
provided for the Owner representative's inspection, at the place of manufacture of the items
being produced for the works, for the selection of the samples for testing in accordance
with related Turkish and EU standards and for the witnessing of tests for evaluating
mechanical properties of the steel.
2.2.2 The materials to be used must be new and in a perfect condition on all sides, i.e. without
any appreciable rust, rolling scale and impurities as well as without any damage and rolling
defects.
2.2.3 All sheets and sections with acceptance certificate 3.1 are to be provided with steel grade,
mark of the supplier and melting charge no. according to TS EN 10204.
2.2.4 All sheets and sections with test report 2.2 are to be marked with steel grade and
manufacturer.

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2.3 INSPECTION CERTIFICATE ACCORDING TO TS EN 10204

2.3.1 Sheets and sections;

Unless otherwise specified in the material specification or in the inspection- and testing
plan, the inspection certificates specified in Table 1 shall be required for the steels to be
processed.

Inspection certificate
Steel grade according to TS EN 10204
S235JR 2.2
S235J0, S235J2+M, S235J2+N, S355JR, S355J0,
3.1
S355J2+M, S355J2+N, S355N, S460N, S690QL
P235GH, P265GH, 16Mo3, 13CrMo4-5, 10CrMo9-10 3.1
TABLE 1

2.3.2 Bolts and nuts:

Inspection certificate
according to TS EN 10204
Bolts / nuts of strength class < 8.8 2.2
Bolts / nuts of strength class ≥ 8.8 3.1
Heat-resistant bolts / nuts according to TS EN 10269
Ck35 3.1
21CrMoV5-7 3.2
24CrMo5 3.2
X22CrMoV1 3.2
TABLE 2

2.3.3 Weld filler metals:

Weld filler metals need an inspection certificate 2.2 with batch number.

2.4 DIMENSIONS AND DIMENSIONAL TOLERANCES OF HOT ROLLED SECTIONS

2.4.1 Structural steel sections, and equal and unequal angles, shall comply with the dimensions
and dimensional tolerances given in related EU standards.

2.4.2 The other basic material to be used must meet the following quality requirements:

TS EN 10034 - Max. tolerance deviations and shape tolerances - I- and H-sections.

TS EN 10048 - Max. tolerance deviations and shape tolerances - steel strip
TS EN 10051 - Max. tolerance deviations and shape tolerances - sheet and ribbon
TS EN 10056-2 - Max. tolerance deviations and shape tolerances - L-sections

2.5 ULTRASONIC TESTING FOR PLATES AND FLATS

Flat products with a wall thickness ≥ 20 mm have to be proved with ultrasonic test. The inspection
is to be performed according to TS EN 10160. Surfaces have to be inspected with a quality class
S2 and marginal zones with a quality class E2.

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3 FABRICATION

3.1 GENERAL

3.1.1 Owner representative shall have access at all reasonable times to all places where work is
being carried out, and shall be provided by the Contractor with all necessary facilities for
inspection during fabrication and off-site assembly. All materials, before and after
fabrication, shall be straight unless required to be curvilinear in form, and shall be free from
twists and other defects. Any necessary straightening or shaping shall be carried out by
methods that neither weaken nor circumstantially deface the material.
3.1.2 At all stages of fabrication, structural steel shall be positively identified by grade, either by
colour marking or by other approved marking system.

3.2 INSPECTION AND TEST PLAN

For shop fabrication, shop erection and erection the Contractor inspection and test plan (ITP) is
applicable. Before fabrication start ITP must be issued for Owner approval. The document
comprises the following specifications:

• Test activity / Inspection

• Requirements/Specifications
• Test Frequency
• Records,
• Conditions,
• Witness/hold points of contractor/sub-contractor,
• Witness/hold points of Owner or its third-party inspector,
• Witness/hold points of notified body on the base of legal determinations,
• The minimum scope of the internal control and contractual guidelines by the manufacturer,
for which manufacturing test and inspection activity the manufacturer has to prepare a
document (test report, record or the like) and which activities are to be included in the
manufacturer's or erection documentation.

3.3 CUTTING

3.3.1 Where the ends of members are to bear in compression, the ends shall be cold sawn and
then machined so that the loads are evenly transmitted over the entire area of the section.
In all other cases, setting may be by shearing, cropping or sawing. Notches or other
shaping to the ends of members shall be formed by cold or hot sawing. Machine Flame
cutting may be used only where approved, in writing by the Owner. Manual flame; cutting
shall not be allowed under any circumstances. Edges shall be free from any defects which
would adversely affect the serviceability of the member. All burrs and similar defects shall
be; carefully removed. The edges of flame cut plates shall, unless otherwise agreed by the
Consultant be machined to remove notches, the heat affected zone or both.
3.3.2 TS EN ISO 9013 contains the provisions and allowable tolerances for the cutting quality
with regard to surface irregularities, grooves and drag lines. For any flame cuts Quality I
and accuracy grade (A) are to be achieved. For plasma arc cuts Quality II and accuracy
grade (D) are to be observed. For plasma arc cuts TS 7227 EN 12584 shall be applicable.
3.3.3 Flame cuts must be deburred regarding the burrs.
3.3.4 For flame cutting the freedom from any corrosion by condensed water must be ensured.
3.3.5 All sharp edges must comply with the corrosion protection requirements (chamfering, as
required).

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3.3.6 Steel S355 is to be preheated for cutting to 100 °C to 150 °C for material thicknesses ≥
20mm.

3.4 CLEARANCES

Care shall be taken to ensure that the clearances specified are worked to. The erection clearance
at ends of beams without web cleats shall not be more than 3 mm at each end, but where, for
practical reasons, this clearance has to be increased, the seating shall be suitably designed.

3.5 HOLES FOR FASTENERS

3.5.1 Holes for fasteners shall not be formed by flame cutting. Holes for the assembly of built-up
sections shall normally be drilled after the members have been assembled and tightly
clamped together.
3.5.2 All burrs shall be removed from holes before assembly except that, where holes are drilled
in one operation through parts which would not otherwise be separated after drilling, the
parts need not be separated to remove the burrs provided that the holes are for black bolts
only.
3.5.3 Finished holes for black bolts shall not be more than 2 mm in diameter larger than the
diameter of the bolt passing through them for bolt diameters up to 24 mm and not more
than 3 mm larger than the diameter of the bolt for diameters over 24 mm unless otherwise
specified by the Owner or required by the design.
3.5.4 Slots, where specified or permitted, shall be formed using a proper slotting machine.
Alliteratively, holes may be drilled and the metal between removed by filling or other
approved method provided that the surface between the circular ends is even and straight.

3.6 MACHINING

3.6.1 Any cuts must be rectangular and deburred on all sides. TS 1980 EN 22768-1 shall be
applicable to the rectangularity.
3.6.2 All sharp edges must comply with the corrosion protection requirements (chamfering, as
required).
3.6.3 Any flange hole patterns must be processed in pairs with the mating flange. Alternatively,
drill templates may also be used.

3.7 MARKING

Each piece of steelwork shall be distinctly marked before delivery, in accordance with a marking
diagram, and shall bear such other marks as shall facilitate erection.

3.8 BOLTING

3.8.1 The parts to be jointed shall be firmly drawn together. Where necessary, washers shall be
tapered or otherwise suitably shaped to give the bolt heads and nuts a satisfactory bearing.
Washers shall be provided under each bolt head and nut unless otherwise agreed.
3.8.2 The length of each bolt and the length of tread shall be such that after tightening at least 6
mm of thread projects through the nut and at least three full threads remains clear between
the nut and unthreaded shank.
3.8.3 All matching holes shall register with each other so that the bolt can be inserted freely
through the assembled members in a direction normal to the faces in contact. Drifting to
align the holes shall not distort the metal or enlarge the holes.

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3.8.4 Load indicating washers shall be used in accordance with the manufacturer's
recommendations and the gap tightening shall be such that the bolt shank tension shall not
be less than the minimum required for the particular size and grade of bolt.

3.9 BEDDING DOWN

After assembly all bolts in the joint shall be tightened with the bedding torque as given on detail
drawings, using a calibrated tightening device. The Contractors attention is drawn to the fact that
during tightening of any one joint the first bolts tightened may relax and may be necessary to re-
tighten each bolt more than once until the bedding down torque is achieved.

3.10 INSPECTION

Before final tightening, the Owner representative shall be informed so that he may check that the
bolts have been correctly bedded down. A tolerance of+/-15% on the specified bedding down
torque will be permitted to allow for slight variations in the calibration of the devices used for
tightening and checking.

3.11 WELDING OPERATIONS

3.11.1 Any fillet welds with a fillet depth a > 3 mm, which are not subjected to any submerged arc
welding, must be made with multiple pass
3.11.2 Stud shear connectors, where specified, shall be welded in accordance with the
manufacturer’s instructions.
3.11.3 For any load-bearing structural parts, columns, crossbeams, diagonal stays, etc. an
allocation of the welder to the seams welded by him is to be ensured. This can be achieved
by a stamping of the seams with the relevant welder's number or allocating of the welder
stamp by marking in a drawing/sketch.

Welding procedure qualification tests (WPQR/ WPAR):

3.11.4 The suitability of welding procedure for the following cases is to be determined by welding
procedure qualification tests (WPQR/ WPAR) according to TS EN ISO 15607 and TS EN
ISO 15614-1:

• For every welding procedure and filler metal (type designation according to the standard)
for steels ≤ S355,
• For every welding position which occurs in the production
• Steels > S355 separated agreement.

3.11.5 Fillet welds shall be qualified separately and shall not be covered by butt welds.

Welder's qualification tests:

3.11.6 Welders must have a valid welder's qualification record according to TS EN ISO 9606-1. In
addition to TS EN ISO 9606-1 it is defined that welders who perform the fillet welding
must have welded a fillet weld test piece. Operators must have a valid operator's
qualification record according to TS EN ISO 14732.
3.11.7 The technical qualification must have been proved.
3.11.8 The scope of qualification must cover the welder’s/operator’s scope of application.

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Welding procedure sheets (WPS), welding sequence plans

3.11.9 For any welding operations to be performed welding schedules and welding procedure
sheets must be prepared by the manufacturer on the basis of his welding procedure
qualification tests (WPQR/WPAR), and the relevant qualification records must be provided
to Owner for review.
3.11.10 A welding sequence plan is additionally required for the main columns, girders and other
components, where any warping must be expected due to welding. The welding procedure
sheets have to include following data: welding procedure, welding filler metal, preparation
and layer structure. For steel grade 10CrMo9-10 and S690QL additional details for heat
management and heat input have to be made.

Weld Filler Metals:

3.11.11 The used filler metals must be approved at the base of harmonized Europeans standards
and correspond to the used one in the Welding procedure qualification test
(WPQR/WPAR).
3.11.12 All filler metals for manufacture and erection should be provided with a marking. A perfect
packing with details of the chemical and mechanical quality coefficients is to be observed.
Any welding material and auxiliary material must be generally stored dry. Any
contaminated (e.g. by oil or grease) or corroded filler metals must not be used.
3.11.13 Basic welding rods and welding powder must be re-baked according to manufacturer's
specifications prior to processing. Electrodes for manual electric welding from the heated
quiver must be welded at the working place – even in case of any tack welding.

Weld Edges:
3.11.14 The weld edge preparation can be done mechanically or by means of flame cutting with
professional flush grinding. In any case the weld edges must be dry and free from any
impurities such as scale, rust, colour, grease, etc. If the temperature of the work piece
during flame cutting is less than +5°C, a lukewarm preheating is required.

Preheating and Heat input:

3.11.15 Basically the steels S235 and S355 are to be preheated, also for tack welding, at a
temperature of 100 - 150 °C under following conditions:
3.11.16 S235 at a wall thickness of > 30 mm and S355 at a wall thickness of > 20 mm.
3.11.17 In case of weld joints with different wall thicknesses, the wall thickness of the thicker
component is the leading wall thickness.
3.11.18 Welding schedules have to contain stipulations about heat input for fine grained steels. The
heat input must be proven by a welding procedure qualification test and supervised and
held in the production.

Tack Welding:
3.11.19 Tack-welding necessitates the same requirements as the final weld seams with regard to
the temperature control and weld filler metals.

Quality of Welds:
3.11.20 Fitted stiffening angles or plates to flanges or sections or brackets shall be accurately
shaped to fit the profile of the member to be stiffened. Unless protection against corrosion
is provided by other means, the interior of any hollow member, whether a structural hollow
section or a fabricated member, shall be sealed so as to prevent the ingress of moisture.

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3.11.21 The ignition of the electrodes must only be performed in the weld groove. Any ignition
points outside the weld seam must be carefully ground. Generally is a surface crack test
performed after grounding with exception for S235 and wall thickness < 30 mm.
3.11.22 All slags, weld spatters, ignition points and deposits due to welding must be removed. Any
auxiliary materials resistant to spatters are subject to the explicit approval by Owner.
3.11.23 Any inadmissible notches must be removed in a professional manner – primarily by flush
grinding, in particular cases by re-welding.

Temperature Control
3.11.24 Preheating and temperature of intermediate layers, rate of cooling and as required heat
control and heat application depend on the specifications of the each applicable welding
procedure qualification test (WPQR/ WPAR).
3.11.25 A sufficiently wide and homogeneous heat distribution (≥ 50 mm on both sides of the
groove as a function of the component thickness and ambient temperature) is to be
ensured.

Weather Criteria
3.11.26 Welding points must be protected against harmful weather influences, e.g. precipitation,
condensation water, draught and wind.
3.11.27 At outside temperatures of less than +5°C the weld bevels are to be dried free from any
condensation water and preheated to a temperature ≥ 40°C.
3.11.28 At outside and object temperatures of less than 0°C the preheating areas are to be
enlarged to approx. 150 - 200 mm on both sides of the welding groove and the
temperatures must be increased. At temperatures of less than – 5°C the weld zone must
be additionally housed and heated.

Repair welding
3.11.29 Any defective locations must be ground and grooved out in a professional manner until the
complete correctness is ensured. Any locations, which are grooved out with carbon
electrodes with copper jacket must be sufficiently ground. After it is generally a surface
crack test to be performed.
3.11.30 The repair welding must be performed by analogy with the original welding as regards the
temperature control and welding parameters and after consultation with the responsible
welding engineer. A different procedure must be on the base of welding test. After the
repair welding is to be a non-destructive test to be performed and documented in the
manufactures documentation.

Straightening:
3.11.31 Cold straightening: The cold straightening is to be preferably applied. Mechanical damage
of the surface (by hammer strokes and stampers, etc.) is to be avoided and must be
repaired by deposition welding and/or regrinding, if required. For steels with a high
toughness such areas must be checked of freedom from cracks by means of magnetic
particle testing or penetrant testing.
3.11.32 Straightening by heat input: Straightening by heat input is only allowed on the base of
approved job instruction with declaration of temperature. It is with neutral acetylene oxygen
flame in such a manner that no damage to the material is caused. Materials susceptible to
cracks (e.g. S355 from 20 mm wall thickness, S235, 16Mo3, S460 from 30 mm wall
thickness) necessitate a visual inspection and a surface crack test on the locations of
preheating. A hardness measurement may be required in justified exceptional cases.

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3.12 TESTING

Evaluation of weld seams, weld quality, non-destructive testing of weld seams

3.12.1 Owner reserves the right to demand test welds. The weld seam quality is evaluated
according to the criteria of standard TS EN ISO 5817 (see also below Table3).

Test standards:
3.12.2 The following standards shall be applicable to non-destructive tests:

TS EN ISO 17637 (VT) Visual inspection

TS EN ISO 3452-1 (PT) Dye penetrant inspection
TS EN ISO 17638 (MT) Magnetic particle test of welded joints
TS EN ISO 17636-1 (RT) Radiographic inspection
TS EN ISO 17640 (UT) Ultrasonic inspection

3.12.3 Table 3 does not qualify for structural steel members of 10CrMo9-10 and S690QL.
Inspections and scopes of inspection for structural steel members of 10CrMo9-10 and
S690QL will be specified in a separately inspection agreement.

Evaluation Grades (acc. To

TYPE
TS EN ISO5817)
Type A (Steel structures: columns, horizontal members/beams,
diagonal bracings, supporting steelwork, silo structure, crane B
girders/beams.)
Type B (Steel structures: walls and intermediate vertical
C
members, roof structure.)
Type C (Platforms, stairs, ladders, open floor gratings,
C
chequered floor, teardrop plates, purlins, girders )
Irregularities on all weld seams
Pores, inclusions, undercuts, linear misalignment, incomplete
B
joint penetrations, root overlap
Cracks, crater pipes(cracks), lack of root fusion, open root
Unacceptable.
gaps, pores, which may lead to leakage
TABLE 3

3.12.4 Unless otherwise specified, in the static stress calculation or the order related inspection-
and test programs, below table shall be applicable.

Type A Type B Type C

VT RT MT VT RT or MT VT RT MT
(%) or (%) (%) UT (%) (%) or (%)
UT (%) UT
(%) (%)
Full Penetration
100 100 20 100 50 20 100 - 20
Butt Welds
Filled Welds 100 - 20 100 - 20 100 - 20
T-Joint Butt
100 100 20 100 50 20 100 - 20
Welds
TABLE 4

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*** If any unacceptable test result is discovered during the non-destructive examination, the scope of examinations will be
doubled. If one or several welds that are examined within the increased scope of examinations fail to meet the
requirements, a 100% examination is required. The reference bases for the increased scope of random tests are the
welders involved, the respective weld seam and the type of weld. Multiple tests and the extended scope of examinations as
well as any costs of the replacement of welders are at the charge of the fabricator. The extended scope of tests is not
imputed on the requested scope of inspections.

3.12.5 The visual inspections must be in-process continuous inspections.

3.12.6 Non-destructive tests on fine-grained structural steels are to be performed at least 72h
after cooling. Fine-grained structural steels must be generally thermally treated
immediately after welding 150°C/4h/air.

4 ERECTION

4.1 GENERAL

4.4.1 All structural steel shall be transported, stored and handled so that it is not subjected to
excessive stress or damage.
4.4.2 All plant and equipment to be used for erection shall have adequate capacity and be
suitable for the contractor's erection procedure. Where steelwork has been painted or
received any other protective coating prior to delivery to the site, the maximum precautions
shall be taken to avoid damage to the paint of the protective coating during loading,
transporting, unloading, stacking and erection. Slings, ropes and chains shall be rubber
sheathed or similar precautions taken during the handling of the steelwork.
4.4.3 Steelwork stored on site shall be raised from the ground on timber bulks or otherwise
protected to avoid mechanical damage to, and chemical contamination of the protective
coating.
4.4.4 Before commencing erection of the steelwork, the contractor shall check the setting out
and levels of the concrete supporting structure, fixing bolts and other bearings for the
steelwork. He shall also examine the area and conditions under which the steelwork is to
be installed. If discrepancies or inaccuracies in site works are found which affect the steel
frame erection and its correct position in relation to the concrete work, these shall be drawn
to the attention of the Owner. Once the contractor has accepted the supporting structures
and ancillary works, he shall accept full responsibility for the accuracy and setting out of the
steel work and fitting of all members.
4.4.5 The positioning, levelling and plumbing of the steelwork and the placing of every part of the
structure shall be within the specified tolerances and to the satisfaction of the Owner. Each
part of the structure shall be aligned as soon as possible after it has been erected.
Members shall not be permanently connected until a sufficient part of the structure has
been erected to ensure that they will not be displaced during the erection or alignment of
the remainder of the structure. The erection of the steelwork shall be carried out in
accordance with the Owner regulations for safety in erecting structural frames. During
erection of the structure, the steelwork shall be securely bolted or otherwise fastened so as
to make adequate provision for all erection loads and conditions including loads due to
erection equipment and its operation.
4.4.6 Any temporary supports such as bracing, guys and props shall remain in position until such
time as the structure is sufficiently far advanced for the temporary supports to be no longer
required.
4.4.7 Connections for temporary supports and measures to facilitate handling and erection shall
be provided in a manner which does not weaken the permanent structure or impairs its
serviceability.

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4.4.8 The Consultant shall have access at all reasonable times and shall be provided with all
necessary facilities for the inspection of the structure during all stages of erection.

5 DIMENSIONAL CHECKS

5.1 GENERAL

5.1.1 After completion of the items and before the preservation is applied the items are to be
inspected by the manufacturer. For this purpose the components are to be cleaned so that
an unrestricted visual inspection and dimensional checks are possible.
5.1.2 Items are to be verified using calibrated measuring tapes (stainless steel) with etched
millimetre-scale.
5.1.3 For all further steel-structures measuring have to be carried out to comply with the
following restrictions. Results are to be logged on assembly drawings and to be handed
over as part of the workshop-documentation. Each measuring is to be signed by the person
performing the measurement indicating date and signature.

5.2 TOLERANCES

5.2.1 Fabrication Tolerances

5.2.1.1 For the classification of the various types of steel structure into tolerance-classes refer
to the types specified in the steel-structure TYPES A, B and C as described in TABLE 3.
5.2.1.2 Items from the main steel structure (type A) have to meet the below requirements:

Columns:
≤ 6.000 mm: ± 1,0 mm
> 6.000 mm - ≤ 12.000 mm: ± 1,5 mm
>12.000 mm: ± 2,0 mm
Beams:
≤ 6.000 mm: +0/−2 mm
> 6.000 mm - ≤ 12.000 mm: +0/−3 mm
>12.000 mm: +0/−4 mm
Diagonals:
+0/−2 mm

5.2.1.3 For all other items from type C the restrictions from TS EN ISO 13920 class A and E
apply.

5.2.2 Shimplates

5.2.2.1 Shim plates for endplate connections of beams:

5.2.2.2 Fabrication variances in the minus area for beams with endplate connections are
acceptable, as long as the total deviation doesn’t exceed the class A of the TS EN ISO
13920.
5.2.2.3 For minus-deviations of more than 2mm the workshop has to provide shim-plates
(according to the results of measuring). These shim plates are to be connected to the
item (wired for shipping or alternative backup with mounting screws). Maximum of 1
shim plate up to 5 mm per member end can be used un-welded.
5.2.2.4 Regarding erection the regulation for using shim plates is not applicable.
5.2.2.5 For normal steel structure type C shim plates are not to be provided.

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5.3 SETTING OUT AND ERECTION TOLERANCES

The setting out, plumbing and levelling of steelwork shall be carried out in a manner so as to be
within the following maximum deviations:

• ± 3 mm for the centre of a support from its true position in relation to either centre line but
not more than is necessary for the connection of any beam truss or lattice girder to the
bearing on the support.
• ±1.5 mm from the specified levels as shown on the drawings.
• ± 6 mm for the overall length and width of the structure.

5.4 INSPECTION PRIOR TO GROUTING

The grouting up to the holding down bolts and base plates for the structures, or any part thereof,
shall not be carried out until the Consultant has approved the setting out and erection. The
Consultant shall be given 24 hours’ notice of the time when the structures or part thereof are ready
for his inspection.

6 PROTECTIVE COATINGS AGAINST CORROSION

6.1 GENERAL

6.1.1 Steelwork shall be protected against corrosion by the application of coatings as shown on
the drawings and specified below.
6.1.2 The following standards and guidelines shall be binding for the corrosion protection, unless
otherwise specified in the present regulations:

• TS EN ISO 12944 - Corrosion protection of steel structures by protective paint systems,

Part 1- 8 as well as corresponding standards.
• TS EN ISO 1461 - Corrosion protection; hot-dip galvanization of individual components;
specifications and test methods
• TS EN ISO 14713 - Guidelines and recommendations for the protection against corrosion
at iron and steel in structures.
• TS EN ISO 8501 - Preparation of steel substrates before application of paints and related
products
• TS EN ISO 8503 - Roughness tests

6.2 SURFACE PREPERATION

6.2.1 The surface preparation of any non-galvanized parts shall be done by means of dry
abrasive blast cleaning.
6.2.2 In this respect, all steel parts including the weld seams are derusted according to TS EN
ISO12944-4 immediately prior to the application of the primer coat by means of dry
abrasive blast cleaning at least until the standard preparation grade Sa 2½ is reached. For
any cast parts of metal an equivalent pre-treatment is taken for granted.
6.2.3 For any non-galvanized parts any rust, welding residues, weld spatters, slag, burrs, salt,
atypical impurities and similar must be removed from the surfaces prior to blast-cleaning.
Rust, weld spatters, slag, burrs must be removed. Any boreholes shall be considered as
surfaces and accordingly prepareted in an equivalent manner. Any existing edges from
flame cuts, saw cuts, punched holes and cutting work, etc. shall be chamfered. Any screw
holes and boreholes shall be deburred.
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6.3 APPLICATION OF COATING

6.3.1 The application of the factory-made coating(s) shall be effected in closed rooms by airless
guns. All corners, clearances, screw holes and hardly accessible areas must be pre-
painted after the surface preparation. The primer coat shall be applied immediately after
blasting. For the application of the intermediate and finishing coats the rework periods shall
be complied with according to the manufacturer's specifications.
6.3.2 For all parts, which receive a two-component coating system on the binding agent base of
epoxy(EP) and polyurethane (PUR) resins, the factory-made coating structure shall be
applied to the extent that during the transport the top coating layer is a coat on the binding
agent base of polyurethane (PUR) resin. It is not allowed to transport any parts that show a
top-coat on the basis of epoxy (EP) resin.
6.3.3 For any coating work the following climatic conditions must be observed: The component
temperature should be min. +10 °C and the max. should not exceed 30 °C. The relative air
humidity should be lower than 80 %.
6.3.4 The specifications of the paint supplier have to be followed with priority.
6.3.5 For the storage and processing of the coating materials the regulations of the coating
manufacturer shall be additionally observed.
6.3.6 Before the start of any corrosion protection work the Contractor must inform the Owner as
follows:
- execution site
- period of execution
- any commissioned subcontractors
- any applicable coating materials and coating systems incl. manufacturer
6.3.7 Inspections of the corrosion protection work shall be made possible to the Owner, the
coating manufacturers and any companies commissioned with the application of the later
finishing coats at any time and without prior notice.
6.3.8 The specified film thicknesses are to be understood as nominal dry film thicknesses
according to TS EN ISO 12944-5. In this respect, any individual values of the dry film
thickness, which are below 80 % of the nominal dry film thickness, shall not be permissible.
Individual values between 80 % and 100 % of the nominal dry film thickness are
permissible, provided the mean value of all measuring results is equal to or greater than
the nominal dry film thickness.
6.3.9 For the max. film thickness the data in the Technical Data Sheet of the coating supplier
shall be applicable. If no data is contained in these data sheets, the max. film thickness
must not be greater than three times the nominal dry film thickness.
6.3.10 For any applied factory-made coating systems with multiple layers the coating materials
shall be purchased from the same manufacturer.
6.3.11 In case of any contact surfaces of pre-stressed screwed connections the contact plate
surface may only be provided with a prime coat. A thickness of max. 60 μm is sufficient
6.3.12 All used fasteners, also galvanized screws, shall receive an equivalent coating structure.

6.4 APPROVED COMPANIES FOR PAINTING

6.4.1 With the exception of components, which are delivered according to supplier standard, the
following paint suppliers are released:
- Akzo Nobel / International
- Sigma Coatings
- Hempel
- Sika Protective Coatings
- Jotun
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6.5 WELDING OPERATIONS AND PAINTING

6.5.1 Any areas, in which site welding is performed, shall be pasted over prior to the application
of the coating at a distance of 5 cm from the welding bevel for the prime coat and each 5
cm for every other coating layer to be applied. It is not allowed to weld over any welding
primers or shop primers.
6.5.2 Where any steel parts are welded to already finish-coated structural steel parts, an area of
min. 10 cm must be free from any coating materials.
6.5.3 The relevant areas shall be pasted over with suitable adhesive tapes for the avoidance of
any major under-rusting. This shall also apply to pipes, headers and similar, which must be
additionally closed with plastic protective caps.
6.5.4 The surface pre-treatment and coating shall be performed in conformity with the system
requirements.

6.6 COATING

6.6.1 The formulation of paint shall comply with TS and EU norms.

6.6.2 All paints forming any one painting system shall be obtained from one manufacturer and
the source of supply shall not be changed. Paint shall be supplied in sealed containers and
shall be used in strict order of delivery.

6.7 COATING SYSTEM

6.7.1 System 1 (indoors)

Description: This specification covers the coating of structural steel work, plate work, not
insulated, system correspondence to C3 according to TS EN ISO 12944.

Examples for Application areas:

- Steel structure inside of buildings
- Stairs, platforms, brackets, girders
- Railings, vertical ladders
- Vertical members, corner connection
- Pipes, pipe supports
- Cold air ducts (inside and outside surface), Tanks
- Temporary support for erection of steel structure
- Etc.

Surface preparation: Blast-cleaning according to ISO 8501-1 grade Sa 2 ½. Surface

roughness according to the specifications of the coat supplier.

System 1
NOMINAL DRY FILM
COATING PAINT NAME
THICKNESS
Two-component epoxy resin (EP) zinc phosphate
Prime Coat 120 μm
primer. Clearly other colour shade than top coat
Top Coat Two-component acrylic-polyurethane (PUR). 80 μm

Sum 200 μm

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6.7.2 System 2 (outdoors)

Description: This specification covers the coating of structural steel work, plate work, not
insulated parts which directly subjected to weather effects, system correspondence to C5-I
according to TS EN ISO 12944.

Examples for Application areas:

- Steel structure outside of buildings
- (outside) Stairs, platforms, brackets, girders
- (outside) Railings, vertical ladders
- (outside) Vertical members, corner connection
- (outside) Pipes, pipe supports
- (outside) Cold air ducts (inside and outside surface), Silos, Tanks
- Etc.

Surface preparation: Blast-cleaning according to ISO 8501-1 grade Sa 2 ½. Surface

roughness according to the specifications of the coat supplier.

System 2
NOMINAL DRY FILM
COATING PAINT NAME
THICKNESS
Prime Two-component epoxy resin (EP) zinc phosphate
100 μm
Coat primer.
Two component epoxy resin (EP) zinc phosphate
Second
primer. 100 μm
Coat
Clearly other colour shade than prime and top coat
Top Coat Two-component acrylic-polyurethane (PUR). 80 μm

Sum 280 μm

The colour scheme will be provided by the Owner.

6.8 REPAIRS TO DAMAGED SURFACES

6.8.1 Areas of paint that have been damaged shall be repaired strictly in accordance with the
manufacturer's recommendations or if no recommendations are made they shall be
cleaned to bare metal, or to metal coating where this has been applied, and the edges of
the undamaged paint bevelled with sandpaper.
6.8.2 Where metal coating has been damaged, the affected area shall be rubbed down to
remove excessive roughness, cleaned and made good by the application of a coat of
approved zinc rich primer. The full specified painting system shall then be applied in such a
manner that the new paint overlaps the existing paint by at least 50mm.

6.9 WORKMANSHIP

6.9.1 Paints or coatings shall be applied according to paint supplier specs.

6.9.2 Each painter shall be skilled and experienced in the method he is using and the supervisor
shall be skilled in each method under his control.
6.9.3 Paint shall not be applied to any surface until that surface has been prepared and cleared
to receive the following coat and damage to previous coatings has been made good. Paint
shall not be applied to a previous paint coat until that coat has dried and cured sufficiently
to receive it. Any maximum time limit between coatings specified by the manufacturer shall

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be strictly adhered to. if this time is exceeded, the surface shall be prepared by a method
recommended.
6.9.4 By the manufacturer to provide an adequate key for the following coat.
6.9.5 The thickness of each coat and the overall thickness of protection shall not be less than the
thickness specified. Stripe coats shall be applied to edges or other areas where the
application may result in thinly applied coatings, if necessary, to ensure that the full
specified coating thickness is achieved.
6.9.6 The environmental conditions shall be such as not to affect the application or the
characteristics of the paint. The manufacturer's recommendations shall be strictly followed.
In particular, coatings shall not be applied to surfaces where the relative humidity of the
atmosphere is such that:

• Condensation is present on the surface

• It will affect the application and/or drying of the paint

6.9.7 When a rising relative humidity reaches a value that produces either of the conditions (i) or
(ii) above, the application of coatings shall be suspended and during the time that the
relative humidity remains at or exceeds that value, work shall not be started or resumed.
Work shall be suspended when sea-spray, dust or other pollutants are contaminating the
surface and the surface shall be properly cleaned and prepared before work resumes.
Coatings shall be protected during drying and curing from the deposition of moisture, dirt,
dust and atmosphere pollutants.

6.10 TREATMENT OF BOLTED CONNECTIONS

The facing surface of the steelwork at friction grip bolted connections shall be masked during the
application of paint coatings. The masking shall remain as temporary protection and be removed
immediately before assembly. Where galvanizing is specified, the facing surface shall be
roughened to improve the slip coefficient before the masking is applied. The masking adhesive
shall be such as not to cause contamination and all traces of the adhesive shall be removed before
assembling the connection. All surfaces for bolted connections are to be prepared and painted after
assembly or erection to the full protection specification. The paint shall have a suitable overlap on
existing painted surface which shall be prepared to provide an adequate key. Crevices at joints and
gaps at load indicating washer shall be sealed with high built paint or mastic, compatible with the
coating system.

6.11 DEFECTS

Protective coatings which on completion are found to be defective as a result of inferior

preparation, quality of materials and/or standard of workmanship or which show signs of early
degradation by blistering, peeling, flaking, cracking or lack of adhesion, shall be applied to the
complete structural member unless remedial work on a patch basis is permitted by the
Architect/Engineer. Where tests on completion indicate that the full dry film thickness of the
protective system has not been achieved, additional coatings may be applied, subject to the
Architect/Engineer's approval to achieve the specified thickness provided that all measures are
taken to ensure inter-coat adhesion and m additional finishing coat, if required, shall form part of
the painting specification.

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7 PROTECTION DURING SHIPMENT AND TRANSPORT

7.1 GENERAL

7.1.1 The fabricated steelwork shall resist, without permanent damage, all stresses induced by
handing, storage and transport. The positions of lifting and supporting points, method of
lifting and the type of equipment and transport to be used shall be specified by the
Contractor.
7.1.2 It shall be the Contractor's responsibility to ensure that all the fabricated steelwork shall not
be subjected to excessive stress of damage during transport and shipment.
7.1.3 During transport and shipment of the units, the following additional factors shall require
consideration:

• Distortion of the transporting vehicle

• Centrifugal force due to cornering
• Oscillation, to prevent the members flexing vertically or horizontally sufficiently to cause
damage.
• The possibility of damage due to chafing.

8 TRIAL ASSEMBLY

8.1 GENERAL

8.1.1 Before commencing shipment of the steelwork, the contractor shall check the assembly of
the manufactured components, in accordance to the approved fabrication drawings.
8.1.2 Any necessary straightening or shaping shall be carried out by methods that neither weaken
nor deface the structural material.
8.1.3 It shall be the contractor's responsibility to ensure that all the fabricated structural steel
delivered to site shall meet the design requirements and approved fabrication drawings.

9 PAYMENT FOR TESTING

The contractor shall include in his rates for the cost of providing and using equipment for the non-
destructive testing of welds (radiographic, ultrasonic, dye penetrate and magnetic particle), during
fabrication and on site as required by the radiographic films and other test results and reports
available to the Owner.

10 WORK INCLUDED

The Items of the Bill of Quantities concerning the Steel members shall include supply, handling,
loading, transportation, unloading, cutting, and fixing according to the drawings at each type, including
protection of steel, all losses, setting out, levelling, carrying out measurement, supply and
transportation of labour, materials, tools and equipment necessary for the execution of the relevant
work, storage, keeping the works in a clean and sanitary condition, cleaning after completion and all
incidental necessary to complete the works according to the Contract Documents, coating, painting,
necessary crainage and erection.

11 MEASUREMENT
Measurement of the reinforcing steel shall be made by weight (Ton) as stipulated in drawings.

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