Faculty of Engineering, Sherif A.

Mourad Fall2022
Cairo University

STR654:
INSPECTION, MAINTENANCE and
REPAIR of STEEL STRUCTURES
Lecture 8b, November 22, 2022

Sherif A. Mourad

Professor of Steel Structures and Bridges

Faculty of Engineering,
Cairo University

SPECIFICATIONS

 StructuralSteel Framing.
 Corrosion Protection of Steel Structures.

 Fire Protection of Steel Structures.

STR654 Lecture 8b 1
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

SPECIFICATIONS
Any specification in general consists of
several sections. The most common
format is called CSI (Construction
Specifications Institute) format:
 General.
 Products.

 Execution.

 Method of measurement

 Basis of payment.

Part 1: GENERAL
1.01 Summary
1.02 References
1.03 Definitions
1.04 System Description
1.05 Submittals
1.06 Quality Assurance

STR654 Lecture 8b 2
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Part 1: GENERAL
1.07 Delivery, Storage and
Handling
1.08 Project and Site
Conditions
1.09 Schedules and Programs
1.10 Special Warranty
1.11 Maintenance

Part 2: PRODUCTS
2.01 Materials
2.02 Fabrication (Shop
Fabrication and Assembly).
2.03 Shop and Field Quality
Control

STR654 Lecture 8b 3
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Part 3: EXECUTION
3.01 Preparation
3.02 Erection
3.03 Fitting
3.04 Punching and Drilling.
3.05 Finishing

Part 4: METHOD OF
MEASUREMENT

Part 5: BASIS OF
PAYMENT

STR654 Lecture 8b 4
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Structural Steel Framing

1.01: SUMMARY
What is covered by this
specification, and what are the
related divisions or sections.
1.02: REFERENCES
Relevant codes and standards
(American: AISC, ASTM, AWS, …)

1.05: SUBMITTALS
Shop drawings, product data, mill
certificates, tests, welding
procedures, welder certificates, ...

1.06: QUALITY ASSURANCE

Reference standards for welding,
fabrication, and erection

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

1.07: DELIVERY
Requirements for delivery, storage,
and handling.
1.08: PROJECT CONDITIONS
Are there any special conditions
that need to be spelled out.
1.09: SCHEDULE
How the schedule is prepared,
submitted, and updated.

2.01: MATERIALS
Structural sections, pipes, bolts,
nuts, washers, primer, shear studs,
grout, ...
2.02: FABRICATION
Cleaning and Straightening Materials,
Cutting, Punching, Drilling and
Tapping, Milling, Use of Burning
Torch, Galvanizing, Welding, …

STR654 Lecture 8b 6
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

2.03: QUALITY CONTROL

Qualifications of the inspector,
independent testing lab, correcting
defects.
Welding: qualifications of welders,
inspection procedures, NDT tests,
rate of testing, …

3.01: PREPARATION
 Verify governing dimensions and
conditions of the Work before
commencing erection Work.
 Provide temporary shoring and
bracing, and other support during
performance of the Work.
 Coordinate prime coat repair and
application with requirements.

STR654 Lecture 8b 7
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

3.02: ERECTION 1/2

Install structural steel accurately in locations, to elevations
indicated, and according to specifications.
Clean surfaces of base plates and bearing plates.
Maintain erection tolerances of structural steel.
Align and adjust various members forming part of
complete frame or structure before permanently fastening.
Before assembly, clean bearing surfaces and other
surfaces that will be in permanent contact after assembly.
Perform necessary adjustments to compensate for
discrepancies in elevations and alignment.
Do not permit thermal cutting during erection of structural
steel. Installation of ordinary and HS bolts as indicated.

3.02: ERECTION 2/2

Correcting detailing and fabrication errors
Erect structural steel plumb and level and to proper
tolerances. Provide temporary bracing, supports or
connections required for complete safety of structure until
final permanent connections are installed.
Install column bases within a tolerance of 1/8 inch of
detailed centerlines, level at proper elevations. Support
bases on double nuts and solidly fill spaces under bases
with cement grout.
Provide anchor bolts with templates and diagrams.
Proper location and installation of bolts.
Correct deficiencies and errors.

STR654 Lecture 8b 8
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

3.03: FITTING
 Closely fit members, finished true to line
and in precise position required to allow
accurate erection and proper joining in the
field.
 Drilling to enlarge unfair holes will not be
allowed. Allow only enough drifting during
assembly to bring parts into position, but not
enough to enlarge holes or distort the metal.
Do not heat rolled sections, unless
approved by the Engineer.

3.04: PUNCHING
 Punch material 1/16 inch larger than
nominal diameter of bolt.
 Drill or sub-punch and ream where metal is
equal to or more than the diameter of the
bolt plus 1/8 inch.
 Precisely locate holes to ensure passage of
bolt through assembled materials without
drifting. Enlarge holes when necessary to
receive bolts by reaming; flame cutting to
enlarge holes is not acceptable. Reject steel
with poorly matched holes.

STR654 Lecture 8b 9
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

3.05: FINISHING
 After erection, spots or surfaces where paint
has been removed, damaged, or burned off,
and field rivets, bolts, and other field
connections shall be cleaned and furnished
with a spot coat of the same primer installed
during shop priming.
 Immediately after erection, clean field
welds, bolted connections, and abraded
areas of shop paint. Install paint to exposed
areas with the same material installed
during shop painting brush or spray to
provide the minimum dry film thickness.

4: MOM 1/5
Measuring of structural steel shall be by
weight unless otherwise indicated.
The weight shall be the net weight, without
addition for rolling margin or welding material
and without deduction for holes.
The weight shall be determined by
calculations using relevant standard tables
and on the basis of the dimensions shown on
the approved detail drawings.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

4: MOM 2/5
In case of non-standardized sections, the
mass shall be taken from the manufacturer’s
data.
Calculations shall be based on a mass of 7,85
kg per m2 of surface and mm of thickness, in
the case of plate, sheet, wide flats and strip.
Calculations shall be based on a density of
7,85 kg/ dm3 in the case of steel shaped
products.

4: MOM 3/5

Addition of calculated weight of 3 % will be

added in case bolted/riveted structural
steelwork to allow for bolts/rivets.
Addition of calculated weight of 1.5 % will be
added in case welded structural steelwork to
allow for welding.
Addition of calculated weight of 2 % will be
added in case welded/ bolted (riveted)
structural steelwork.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

4: MOM 4/5

 Measuring of works will be based on the

following units:
 Mass (kg or t), accounted for: structural steel
and fitting and fixings
 Area (m2), accounted for: composite members
consisting of steel and concrete, - steel deck
units
 Number of items (pc), accounted for: wedging
and grouting bases, anchor bolts and the like,
including temporary boxes and grouting

4: MOM 5/5
 Protective treatment / Painting will be
measured as Lump Sum.
 Protective treatment / corrosion protection
will be measured as Lump Sum including
additional protection of edges, fasteners,
and welds.
 Protective treatment / Fire protection will be
measured as Lump Sum.
 In case that the Contractor is responsible for
the structural design, all measurements will
be as Lump Sum.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

5: PAYMENT 1/3
 The Contract price for supply, fabrication
and erection of structural steel shall include
all labor, material, transportation, protection,
inspection, quality assurance, shop, and
field painting necessary for proper
completion of the work.
 Material or work which does not conform to
specification requirements, shall be
removed or replaced on Contractor’s
expense.

5: PAYMENT 2/3
 Unit price rates include:
 Providing the test pieces, personnel,
equipment and tools required for testing
during erection and for acceptance.
 Providing calculation of mass to be used
for the settlement of accounts.
 Providing structural design, structural
analysis, and structural, shop, and
erection drawings for the approval of the
Engineer.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

5: PAYMENT 3/3

 Unit price rates include:

 Providing shop, and erection
drawings to the approval of the
Engineer.
 Corrosion protection by protective
paint system.
 Fire protection of structural
members.

SPECIFICATIONS FOR
COATING STRUCTURAL
STEEL
 Submittals.

 Materials.

 Construction method.
 Quality control.

 Method of measurement.

 Basis of payment.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

SUBMITTALS
 The Contractor shall submit the following to the
Engineer, in accordance with Special Provisions:
 Prior to abrasive blasting, the Contractor shall submit
written certification from a certified laboratory, stating
that the abrasive media meets the material requirements
shown on the Drawings and described in this
Specification.
 Before commencing the application of the coating
system, the Contractor shall submit written
certification, from the coating manufacturer, stating that
all materials supplied are as specified on the Drawings,
described in this Specification and in accordance with
the Manufacturer’s current product data sheets.

SUBMITTALS
 The Contractor shall submit the Manufacturer’s
product data sheets describing the following:
 Recommended maximum dry film thicknesses for each
coating layer
 Mixing and thinning directions

 Recommended spray nozzles and pressures

 Acceptable humidity level and temperature range for

application
 Minimum acceptable recoat time period for
temperatures between 5ºC to 30ºC in intervals of 5ºC,
including the acceptable range of relative humidity for
each temperature interval.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

SUBMITTALS
 The Contractor shall submit the details of surface preparation and
coating system application to areas difficult to access.
 The Contractor shall submit the proposed environmental
protection measures to be taken during surface preparation and
coating of structural steel in the field. The detailed submission shall
include a description of the environmental protection measures to
be undertaken so as to ensure complete containment, collection
and disposal of spent blasting abrasives, removed paint, all other
debris products from surface preparation as well as new coating
system over spray. The detailed submission shall also include a
detailed description of the proposed methods and procedures,
sequence of operations, equipment, detailed drawings of the
proposed enclosure system and all other applicable details relating
to environmental protection measures during surface preparation
and coating.

SUBMITTALS
 The Contractor shall submit a written guarantee from the supplier
of the coating system within fourteen (14) days of completion of
coating operations stating that the product will perform
satisfactorily for a minimum period of five (5) years from the
completion date, provided that both the surface preparation and
application of the paint has been carried out in accordance with the
Manufacturer’s recommendations.
 The Contractor shall provide to the Engineer a guarantee in
writing, stating that the coating system will perform satisfactorily
for a period of five (5) years from the date of completion. The
Contractor shall provide in the guarantee for the reapplication of
the paint system at no cost to the Department in the event that the
coating system does not perform satisfactorily. This shall include,
but not necessarily be limited to: the supply and installation of the
working platform, hoarding, scaffolding; removal, and disposal of
the unacceptable coating system; surface preparation; coating; and
all other items necessary to reapply a coating system.

STR654 Lecture 8b 16
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

MATERIALS

 Water

 Abrasive Media
 Coating System

 Incidental Materials

CONSTRUCTION METHOD

 Environmental Protection During

Surface Preparation and Application of
Coating System in the Field.
 Surface Preparation and Surface Profile

 Application of Coating System

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

QUALITY MANAGEMENT

 The Contractor shall be responsible for quality

control testing required to ensure the Work meets
the requirements shown on the Drawings and
described in this Specification, including the
required surface preparation.
 The Contractor shall arrange for the coating system
manufacturer to provide technical assistance prior
to and during the coating system application
operations.

QUALITY MANAGEMENT
 The Contractor shall arrange for a representative of
the coating system supplier to visit the site during
coating operations so as to ensure that the surface
preparation and coating system application is in
accordance with the Manufacturer’s
recommendations.
 The Contractor shall record the quality of surface
preparation and measurements of surface profile,
temperature, humidity, dew point and dry film
thickness. Written documentation of the results of
quality control inspection shall be submitted to the
Engineer on a daily basis.

STR654 Lecture 8b 18
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

QUALITY MANAGEMENT

 Dry film thickness (dft) measurements shall

be measured using Type 2 constant pressure
probe magnetic gauges. Dry film thickness
measurements shall be undertaken in
accordance with SSPC-PA 2.
 Adhesion of coating systems may be tested in
accordance with ASTM D 4541 at the
discretion of the Engineer.

QUALITY MANAGEMENT
 Measurement of Dry Coating Thickness with Magnetic
Gauges. Determination of the acceptability of the dft of
each coat shall be made in accordance with SSPC-PA 2.
The specified minimum and maximum dft used to
determine acceptability of coating thickness according to
SSPC-PA 2 shall be the Manufacturer’s recommended
minimum and maximum dft as shown on the submitted
product data sheets. To facilitate the calibration procedure,
the Contractor, at a location selected by the Engineer, shall
mask off a 75mm x 75mm area of the prepared steel. After
all tests are completed, this area shall be coated as
specified for the coating system.

STR654 Lecture 8b 19
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

QUALITY MANAGEMENT
 Inspection Requirements for Coating
Application outside the site, expenses incurred
by the Engineer’s representative to carry out
testing and inspection will be paid by the
Contractor.
 Expenses will include, but are not necessarily
limited to, all travel, boarding, lodging and the
retention of services from a certified agency of
the Engineer’s choice for testing and inspection
at the coating application location.

METHOD OF MEASUREMENT
 Environmental protection during surface
preparation and coating of structural
steel will be paid for on a lump sum basis
and no separate measurement will be
made for this work.
 The coating of structural steel will be
paid for on a lump sum basis, and no
separate measurement will be made for
this work.

STR654 Lecture 8b 20
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

BASIS OF PAYMENT
 Environmental protection during surface preparation and
coating of structural steel will be paid for at the Contract
Lump Sum Price for “Environmental Protection –
Surface Preparation and Painting” measured as specified
herein, and will be payment in full for performing all
operations herein described and all other items incidental
to the Work.
 The coating of structural steel will be paid for at the
Contract Lump Sum Price for "Surface Preparation and
Painting of Structural Steel" measured as specified herein,
and will be payment in full for performing all operations
herein described and all other items incidental to the
Work.

Fire Protection of Steel Structures

1.0 SCOPE
This specification covers materials and methods of application for
fireproofing of steel structures and equipment supports.
2.0 APPLICABLE CODES
Note: - Wherever reference is made to IS Codes, on any page of this
Technical Specification (including annexures), applicable year of
publication of Code is as stated below.
The Egyptian Standard Codes applicable to this section shall include
but not limited to the following:
ES ??? – 19?? : Hard drawn steel wire fabric for concrete Rft.
ES ??? – 19?? : Specification for guniting equipment.
ES ??? – 19?? : Recommended practice for shotcreting.

STR654 Lecture 8b 21
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

3.0 PRIORITY OF REQUIREMENT
In case of any variation and discrepancy in condition between the special
conditions, this specification and codes, order of priority shall be as:-
(1) Special conditions
(2) This specification
(3) Codes
4.0 GENERAL
4.1 Purpose
Fire proofing is aimed at providing resistance to all the load bearing steel
structures and equipment supports that would collapse under fire
conditions and contribute to the intensity of the fire.
Fire resistance would allow evacuation and fire suppression. Therefore,
supports of all potential fire sources shall be fireproofed. Support of non-
potential fire hazards shall also be fireproofed, if their collapse is likely to
endanger other hazardous equipment.

Fire Protection of Steel Structures

4.2 Fire Resistance Rating
A minimum of 2 hours fire resistance , shall be applied, unless specified
otherwise.
5.0 CRITERIA OF FIRE PROOFING
5.1 Pipe Racks
5.1.1 Pipe rack main members such as columns, girder, beams and vertical
bracings withstanding long term loads shall be fireproofed upto the first
pipe support level, in the fire hazardous area, unless specified otherwise.
5.1.2 Where equipment such as Air Fin coolers are supported on the pipe
rack, fire proofing for columns shall be extended upto the equipment
support level and the structural members transmitting the equipment
loads shall be fire proofed.
5.1.3 The top flanges of beams supporting the pipes shall not be fire
proofed.
5.1.4 Pipe racks outside the fire hazardous area shall not be fire proofed.

STR654 Lecture 8b 22
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

5.2 Equipment Supporting Structures
5.2.1 Where structure supports the equipment classified to the
potential fire hazard, columns shall be fire proofed from the base
plates to the equipment support level.
The beams and bracings transmitting the equipment loads to the
columns shall be fire proofed.
5.2.2 Platforms, stairways and their supports shall not be fireproofed.
6.0 SURFACE PREPARATION
6.1 Steel surfaces to be fire proofed, shall not be painted and shall be
cleared of all loose dirt, rust, mill scale, soot and concrete by
mechanical wire brushing or shot blasting. Oil and grease deposits
shall be removed with detergents and steel surface made clean and
dry.

Fire Protection of Steel Structures

6.2 Pipes and equipment in the vicinity shall be covered by

tarpaulins to prevent them from spatter. Rebound and spatter
which may enter open ends of pipe lines in the vicinity shall be
protected by wood plugs or other suitable shields.
7.0 FIREPROOFING BY GUNITING
7.1 Materials, equipment and method of application shall be in
accordance with ES ??? and ES ???. Placement shall be done only
by skilled operators as approved by Engineer-In-Charge

STR654 Lecture 8b 23
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

7.2 Hard drawn steel wire fabric of 2.5mm dia, 50 x 50mm
mesh conforming to ES ??? shall be used as reinforcement.
The fabric shall be secured by 18 SWG galvanized tie wire
to studs or spacers. Spacers shall be 5mm thick. Steel wire
fabric reinforcement shall be placed, to maintain a clearance
of not less than 20mm from face of member. Adjacent
sheets shall be lapped at least 75mm and securely tied.
7.3 Shooting strips shall be used to obtain proper thickness
and true lines over flanges, angles and re-entrant corners.
Strips shall be designed to permit escape of rebound.
7.4 The finish shall be wooden float or sponge trowelled
sufficient to obtain a uniform appearance without attracting
excessive laitance to the surface.

Fire Protection of Steel Structures

7.5 Immediately after final finishing, surfaces shall be given a
one spray coat of an approved curing compound.
Brand name, name of manufacturer and test results shall be
submitted to and got approved from the Engineer-In-Charge prior
to procurement and use of curing compound.
7.6 Shotcrete thus applied shall develop not less than 24 N/mm²
compressive strength in 28 days.
7.7 All outside edges of fire proofing shall be chamfered /
rounded off by 20mm.
7.8 The fixing of the reinforcing fabric shall be robust and in
sufficient quantity to secure the fabric in the required position at
all stages of the fire proofing application.

STR654 Lecture 8b 24
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

7.9 The junction between fireproofing and bare steel shall be sealed
against ingress of water, with minimum 10 mm thick mastic flashing.
When not otherwise shielded.
7.10 Bags of cement shall be kept dry until ready for use, stored off the
ground, under cover and away from wet or damp surfaces or areas of high
humidity.
7.11 The mixing shall be made in concrete paddle blade mixers in
accordance with the manufacturer’s instructions. The water added shall be
of potable quality.
7.12 Unless specified otherwise, the thickness tolerance shall be –
2/+3mm. Each face shall be checked for thickness every 4m and at least
once per member.
8.0 FIRE PROOFING BY IN-SITU CONCRETE (ENCASING)
8.1 Concrete for fire proofing shall be M20 grade. Mixing and placing
shall be done as per TEIL specification no. A-318.
8.2 Minimum thickness of concrete coating over the steel shall be 50 mm.

Fire Protection of Steel Structures

8.3 Concrete shall be poured into forms properly oiled and made to
correct dimensions. Concrete shall be vibrated as necessary to
ensure smooth surface, free from voids and irregularities. Any
defects, honey comb etc. shall be rectified by the contractor at his
own cost.
9.0 VERMICULITE CEMENTITIOUS COATING
9.1 Design Specifications :
9.1.1 Vermiculite cementitious coating shall restrict the temperature
of a vessel / structure below 427o C for vessel supports & skirts and
550o C for structural steel members, for a minimum time of 2
hours. The material shall not fail till the end of specified time
period.
9.1.2 The coating shall be strong enough to withstand thermal shock
and impingement of water from fire hoses and / or monitors.

STR654 Lecture 8b 25
Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

9.1.3 The coating shall be asbestos free and shall be non
corrosive to steel members and shall not be affected by
environmental conditions, or from local leakages, spillage or
pollution.
9.1.4 The coating material shall be easily repairable and shall
be durable.
9.1.5 Application procedure of the coating shall be non
hazardous, shall not interfere with the working of adjoining
areas and shall be easy.
9.1.6 The LSTK contractor shall submit calculation for the
thickness of coating for all structures to be fireproofed for
approval from the Engineer-In-Charge for the
particular branded product he is going to use, but in no case
the coating shall be less than 40 mm.

Fire Protection of Steel Structures

10. APPLICATION
Vermiculite cementitious coating shall be mixed with water in a
suitable mixer or on clean platform as per manufacturer’s
specifications. Water cement ratio shall be adjusted so that
vermiculite cementitious coating adheres properly to steel surface
and does not sag or slide after applying.
Application of primer suitable with vermiculite cement coating as
specified by manufacturer shall be applied over the steel surface
after cleaning the shop primer, it required as per the manufacturer’s
specifications.
Generally spray gun shall be used for the application of the mixed
vermiculite cementitious coating, except for small or inaccessible
locations, where application with hand tools shall be permitted.
Mixed vermiculite shall be used within the pot life specified by
manufacturer. Under no circumstances rebound material shall be
used.

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

The full specified thickness shall be developed in three successive coats.
 Initial Coat : Thickness between 8 mm to 12 mm.

 Intermediate Coat : Thickness between 18 mm to 22 mm to give total thickness of 30

mm up to Intermediate coat.
 Final Coat : Not less than 8 mm thick.

Each successive layer shall only be applied after the previous layer has developed its
initial set and is also properly scratched with steel brush to roughen the surface to develop
proper bond. If the application is interrupted and does not satisfy successive layers criteria,
the coating shall be cut back to the steel surface proceeding layer with a trowel at an
inclined angle. Exposed surface of this coating shall be thoroughly wetted before resuming
the work.
Application of mixed vermiculite shall not be carried out if the air temperature is 4o C or
less. Provision shall be made for adequate ventilation during and after application, until
the coating is dry.
2 coats of micro-porous exterior top coat, compatible to cement surfaces, of approved
make & color conforming to IS specifications, should be applied, over the fire proof
coating.
Sealing with minimum 10 mm thick bitumen mastic flashing, shall be carried out at all
exposed joints between fire proofing material coating & steel.

Fire Protection of Steel Structures

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

Fire Protection of Steel Structures

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

Fire Protection of Steel Structures

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

Fire Protection of Steel Structures

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Faculty of Engineering, Sherif A. Mourad Fall2022
Cairo University

Fire Protection of Steel Structures

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