GODREJ PROPERTIES LIMITED SOP No.

: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

PORTAL FRAME STRUCTURE

KEY QUALITY RELATED DEFECTS IN STRUCTURAL STEEL WORKS

1. Bare spots on the surface of steel works

2. Brushes/roll marks during painting of steel works
3. Buckling in surface of steel works
4. Edge wave for steel works
5. Pinchers.
6. Cavities or blow-holes
7. Un even Welding joints
8. Rust/ corrosion of steel surface due to improper storage
9. Dimension mistakes due to improper workmanship

METHOD STATEMENT

 PREPARATION
o Site Planning & Preparation
o Make sure there is space and firmed pathway for truck delivery, crane truck erection
operation.
o The suitable truck & crane capacity must be clarified.
o The plan for unloading and materials storage on the site should be suitable and dry
location.
o Steel component or materials shall be stored separately for difference sizes and types.
o Materials shall be stored in designated areas for each building and clearly identified for
their location as per planning.
o Dry area and stored above ground level with timber packing and ventilated.
o The materials should be placed in minimum 5% slope to avoid water pond.
o For unloading materials out of trucks, the platform or access road must be prepared
properly for crane and trucks by term safely load.
o Unloading can be done manually by term with using 25-tonnes cranes.
o A spreader should be used for long steel components.
o Lifting nylon or cloth belts with suitable SWL shall be used for unloading the materials to
minimize the damage.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o Be sure to hook belts to component with the right number of points and position so that
the load of the component itself do not damaged or broken especially the
coating/discolour.
o The materials shall be kept free from the dirt, dust, grease and other foreign materials.
o The fabricated I-beam or columns should be arranged close to their anchor bolt position.
o Rafter should be arranged to ensure easy to assemble and move.
o Level and position of nuts and anchor, lifting weight and crane position shall be
checked.
o After the columns are being distributed along the designated positions, the materials
need to be cleaned and assembled before erection.
o The scaffolding should be prepared for workers to perform rafter to rafter, rafter to
column connections.

 INSTALLATION
o Lay out your side wall girts and roof purlins onto your slab.
o Check your BOM to ensure you have the correct length sections. Then, join them
together with overlap to suit the length of the building, ensuring all overlaps are equal on
buildings with more than 2 bays.
o For ease of handling it is recommended that girts & purlins be joined together in
multiples of no more than 2 at a time. Once joined, mark the position of the intermediate
portal frames onto the Top hat or Z Section using a permanent marker.
o Lay 2 rafters and 1 apex bracket (assuming single frame) web side up on the foundation
at the approximate roof pitch ensuring the C Sections meet at the apex.
o Place 2 screws (one in each rafter) securing the apex bracket into position.
o Measure long point to long point of rafters, adjust until measurement equals RAFT-DIST.
o “Tek” screw or bolt the apex bracket securely into position (as per engineering plans).
o Stand rafters side by side and mark the position for the roof purlins on the rafter with a
permanent marker or crayon, (quantity and spacing as per engineering plans) and put
aside until required.
o The diagram below shows an optional way of inserting a temporary frame screw at the
bottom of each purlin.
o Lay down columns flat on the slab, both side walls at the approximate bay spacing.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o Attach a haunch bracket to the web face of each column.

o When placing the left & right handed haunch brackets onto the columns ensure that the
web face of each column will face the front of the building when built.
o Ensure that the top of the bracket is flush with the top of the column.
o One “Tek” screw is placed in the bracket to hold it in place. Then it is fully fixed off
according to engineering plans.
o Fix a base cleat bracket to the web face at the base of each column. Where double
columns are used base cleats are fixed to the inside of both C Sections.
o An eave purlin bracket is attached to the top of each column using 2 frame screws per
side of the bracket.
o The eave purlin bracket needs to be at the height stipulated in the member
o Make each of the portal assemblies on the ground. Check them for square and bolt them
together.
o Line up the bottom of the columns with the edge of the slab, and measure the diagonals
for square.
o Trace around the completed portal assembly once it has been squared up and remove
from this location. You now have a template to make the subsequent assemblies.
o The 25-tonnes crane is set-up with the suitable position to lift the column into position.
o Before major lifting, all the slings 1 rope is inspected by riggers.
o Temporary anchor points should be arranged out of working area to avoid hanging
materials can be caught by temporary cable.
o The fabricated sections are joined together at the site along the grid lines.
o The connected frame will be slightly lifted by two cranes (25-tonnes) into position and
bolts tightened.
o Two units of mobile scaffold platform to the joint height will be pushed to place to do the
nuts tightened.
o Workers on the ground will drive the fabricated steel (rafter) to the right position in
coordination with the crane.
o Crane is only released when all connection bolts and nut adequate tighten.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o Brace bay will be erected in priority. After completion bracing bay frames, all
components such as brace rod, flange brace, etc of this shall be completed as per shop
drawing.
o Braced bay frames must be temporarily aligned before installation purlins and bracing to
avoid difficulties may get if conducting alignment for remained frame.
o The first of the portals is positioned on the edge of the slab stand the assembly and prop
securely using timber or ropes tied securely around stakes driven into the ground.
o Drill holes through base cleats on each column and secure with appropriate anchor
bolts (as per engineering plans).
o Ensure that all holes are clean before placing masonry anchors.
o Check that all anchors are tightened down sufficiently and check columns are plumb
using a spirit level.
o The centre of the rafter in each portal frame assembly should be supported temporarily
until all frames and Gable End Wall mullions are in place to stop the rafters rotating on
the haunch brackets.
o If no Gable End Wall mullion is required the rafters must be temporarily supported until
all frames and roof purlins are in place.
o Install the second of the portal assemblies measuring carefully at the top and the bottom
of each portal frame to ensure the spacing between the portals are equal and plumb.
o Once in position, install a number of the roof purlins to hold it into position.
o Proceed with the erection of the remaining frames and additional bays. Eave struts and
peak purlins may be installed in the immediately bay between braced bays to stabilize
frames.
o Install the eave purlins onto the eave purlin brackets located at the tops of the column.
o The eave purlin is attached to the eave purlin bracket using 1 framing screw on each
end.
o The size of the eave purlin is dependent on the size of the structure, and may not be
identical to the other C Sections, Z Sections or Tophats.
o Mark side wall girts spacing on the columns.
o First row of girts is 200mm from floor level and the rest of the girts are to be equally
spaced (as per specification).
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o The end of the girts will be flush with the outside edge of the end columns. i.e., overall
length of the slab. Use 1 frame screw at each gable end wall column to hold the girts in
place.
o Use a string line to make sure the bottoms of the columns are in a straight line.
o Measure the diagonals of the wall frame ensuring that both measurements are equal.
o If not, adjust the wall until the measurements are equal, making sure the base of the
columns remain straight to the string line.
o Once the frame is completely square, finish fixing the side girts and eave purlins to the
columns as per specification
o If side wall bracing is required, fix into position (as per specification) prior to cladding
walls.
o Fix the base cleat to the bottom of the Gable End Wall mullion. Attach the mullion fixing
angle bracket to the top of the Gable End Wall mullion on the web face.
o Gable End Wall mullions are to be spaced (as per specification), and are offset by the
size of the end girt from the edge of the slab.
o Fit Gable End Wall mullions so that the web of the C Section is perpendicular to the
Gable End Wall girt, with the web face of the mullion facing towards the prominent
opening of the building.
o Stand the Gable End Wall mullions into position. Drill holes through base cleats on each
mullion and secure with appropriate anchor bolt (as per specification). Ensure that all
holes are clean before placing masonry anchors.
o Check that all anchors are tightened down sufficiently. Check mullions are plumb using a
spirit level on the web face.
o Attach the mullion fixing angle bracket to the rafter (as per specification). Check mullions
are plumb using a spirit level on the flange side and securely prop mullion into position.
o Fix the Gable End Wall girt brackets to the inside flange face of the Gable End Wall
columns as shown, spacing as per engineering plans.
o Attach the Gable End Wall girts to these brackets, overlapping the girts on the Gable
End Wall mullion.
o If Gable End Wall bracing is required, fix into position (as per specification) prior to
cladding the wall.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o Starting from one corner of the building, begin sheeting the walls. Make sure that the
female rib of the cladding is facing away from prevailing weather, and that sheeting is
flush with the top of the eave purlin.
o This will ensure that the sheets will overlap the foundation of the building, and prevent
water entering the building.
o Using the required number of wall screws (as per specification), fix the wall sheets one
at a time using a straight edge/chalk line to ensure screws are placed in a straight line.
Cut the last wall sheet flush to the end of the wall girts.
o Overall length of the gutters is the overall length of the building from outside to outside
edge of Gable End Wall sheets.
o Gutter overlap should be joined using Silicone & Pop Rivets.
o Count the number of brackets supplied per side of building and space brackets evenly.
Gutter Brackets are to be spaced at a maximum of 1m intervals.
o Mark a chalk line starting from the top of the wall cladding at one end, with a slight
downward slope towards the downpipe end (minimum 3°).
o Following the marked line attach gutter bracket to ribs of wall sheets with pop rivets.
o Apply silicone to gutter joints prior to installing gutter. Clip gutter onto gutter brackets
ensuring gutters overhang Gable End Walls by a thickness of wall cladding.
o Fold Gutter Bracket tags down onto the Gutter to hold it into position.
o If roof bracing is required, fix into position (as per specification) prior to sheeting the roof.
o If skylights are supplied in your building ensure that all safety precautions are taken in
accordance with local regulations.
o During handover 2 coats of enamel paints shall be done

 CHECKS AFTER INSTALLATION OF PORTALS

o Make a final check of the structure
o Ensure that all base cleats have been tightened down firmly
o Check that the roof and wall screws are complete
o Brush the complete structure down, including the roof with a soft hair broom to remove
any swarf.
o Hose down the concrete slab to remove any steel particles, screws and rivets, which
may puncture a tyre.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

ENAMEL PAINT APPLICATION

 Preparatory works
o Ensure all the relevant drawings are available with required specification
o The required safety PPEs (Dust mask, Safety glass and hand gloves) shall be available
at site.
o Make sure all the required tools (Sprayer, Rollers, brush, sponge etc.) are available
o Required quantity of the approved make of enamel paint shall be made available at site
o Shelf life (Life of Paint in Sealed Condition) / pot life (Life of Paint in Opened condition)
of Primer, Thinner and Paint given by manufacturer have to be followed at site

 Installation Procedure
o The surface shall be checked if any Foreign particles settled over the grills to be
removed
o Presence of patches and cracks on the surface should be treated with stopping and
filling with the filler prepared by the specified paint.
o Where joints are welded should be grinded to remove fluxing material before painting.
o Presence of Rust and Scale to be removed by scraping, chipping, wire-brushing, rubbing
with abrasive paper or steel wool, by flame cleaning.
o Sanding shall be done to the surface with 150-220 count sand paper and it to be
cleaned
o Before starting the enamel paint works the surface shall be dust free and dry.
o Primer for Enamel paints normally come ready mixed so it can be used directly after
mixing it thoroughly using wooden piece. Avoid any unauthorized thinning or
adulteration.
o Apply one coat of primer of approved brand using a brush or roller to facilitate good
bonding between the surface and paint. Let it to dry for minimum 12 hours or as per
manufacture specs.
o After the primer coat completely dried, apply 1st coat paint of approve brand using roller,
brush or spray to the surface and let it dry for minimum 12 hours or as per manufacture
specs.
o After the 1ST coat completely dried, apply 2nd coat paint using roller, brush or spray to the
surface and let it dry for minimum 12 hours or as per manufacture specs.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o Junctions of different colors has to be painted with zero point brush to achieve the
proper line
o The color tone throughout the surface should be checked for the uniformity.

 Post Painting
o The concentration in the mixture must be uniform.
o No overlapping to be seen.
o Check for any smudges.
o Check for spillages cleaned after painting work completed.

 MATERIAL STORAGE GUIDELINES:

o Portal frames shall be examined for any damage that may have occurred in transit and
shall then be stacked upright on level ground.
o Portal frames shall be properly stored in a separate room to avoid corrosion, which shall
be well ventilated, free from excessive heating & away from direct sun light.
o Portal frames is not allowed to get into direct contact with wet cement mortar spillage.
o Portal frame sections shall be stacked off the floor on wooden planks in such a way as to
keep about 150 mm to 200 mm clear above the floor.
o Primer & Paint shall be stored in a separately made store. The store shall be well
ventilated, free from excessive heating, direct sun rays and any source of fire/spark.
o Primer & Paint of different colour codes shall be stacked differently.
o Primer/Paints shall be checked before opening them for expire date, colours, black listed
and the accepted brands.
o The primer /paint containers shall not be opened except when using it.
o The primer & paint buckets shall be kept on a regular wooden platform
o The paint shall be used before expire date and self-life should be marked on the
container. Primer & paint should be used with 12 months or as per manufacture specs.

 MATERIAL SELECTION GUIDELINES:

o IS 1161- 1998: Steel tubes for structural purposes -Specification
o S: 816-1969 – Specifications for Welding of Metal works
o ASTM A 193 - Grade B7 (high strength carbon steel anchor)
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

o ASTM E 488: Pull Out Strength of Anchors in Concrete and Masonry

o Specifications: IS (814:2004) welding electrodes for metal arc welding & carbon
manganese steel
o Specifications: IS 2074:1992 – Specifications (Ready mixed paint, Air drying, Red oxide
zinc chrome, Priming)
o Paint, Anchor fastener, sealant adhesive and Ready mixed paint are received at site to
have a MTC.
o Anchor fastener- Pull-out test on RCC & Masonry to be done once per brand, MTC to
verify for every batch, and has to be conformed to ETA requirements.
o Note: ITP to be overlooked with the listed Testing Guidelines, if ITP is missing for any material
the Test Guidelines will be adhered, If not listed as per MAS SOP No.: GPL-PROCESS-
MATERIALAPPROVAL-056 and MIR

 TOOLS & TACKLES

 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

A TYPICAL CYCLE
 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

FABRICATION / ASSEMBLY SEQUENCE:

ASSEMBLY OF PORTAL FRAMES

BRACINGS INSTALLATION TO THE FRAMES

 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS

ALL ANCHORS ARE TIGHTENED DOWN SUFFICIENTLY

GABLE END WALL BRACING IS FIX INTO POSITION

 GODREJ PROPERTIES LIMITED SOP No.: GPL-STRUCTSTEEL-PORTAL FRAME-033A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : STRUCTURAL STEEL WORKS
Date: 27/03/2020
- PORTALS