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NPQS C5-10 Structural Steelwork

National Productivity and Quality Specifications (NPQS)

C5-10 Structural Steelwork

NPQS C5-10 Structural Steelwork

CONTENTS

 

Page

1.

GENERAL

1

1.1

Scope

1

1.2

Related Sections

1

1.3

Standards and Technical Reference

1

1.4

Trade Preambles

3

1.5

Definitions

6

2.

PERFORMANCE REQUIREMENTS

7

2.1

Design Brief

7

2.2

Loading During Construction

7

3.

MATERIALS

8

3.1

Steel Sections/Elements

8

3.2

Welding Consumables

9

3.3

Fasteners

9

3.4

Profiled Steel Decking

10

3.5

Protective Finishes

10

3.6

Grout

10

4.

WORKMANSHIP

12

4.1

General

12

4.2

Storage and Handling

12

4.3

Fabrication

12

4.4

Bolting

14

4.5

Welding

16

4.6

Permitted Deviations (PDs) of Fabrication

19

4.7

Erection

26

4.8

Permitted Deviations (PDs) in Erection

27

5.

VERIFICATION AND SUBMISSIONS

32

5.1

Submission

32

5.2

Procedural Trial and Trial Assemblies

34

5.3

Inspection

34

5.4

Non-Destructive Testing of Welds

34

NPQS C5-10 Structural Steelwork

1.

GENERAL

Read with the General Requirements section, and all other contract documents.

1.1

Scope

This section covers the requirements for the fabrication and erection of normal structural steelwork in buildings. It does not cover the use of stainless steel in special structures.

This document specifies project specific data to be read in conjunction with section C5-10 of NPQS. All modification and additions noted in this document take precedence over clauses noted in NPQS. Clause references in this document tie with those in C5-10 with the same clause title.

1.2

Related Sections

 

Read this work section in conjunction with the relevant requirements of the other work sections as follows:

C5-20

Protective Works for Structural Steelwork

1.3

Standards and Technical Reference

 

1.3.1 Standard

Unless otherwise agreed by the SO, ensure all of the Works comply with the relevant requirements of the Standards and Codes listed below or referenced in the body of the Specification. Alternative Standards and Codes may be proposed for approval by the SO, provided it can be demonstrated that the alternative Standards and Codes comply with the requirements of the standards specified. All Standards and Codes quoted are the current version, unless specific year references are noted.

Singapore Standards

SS 470

Hot-finished structural hollow sections of non-alloy and fine grain structural steels

Part 1: Technical delivery requirements

Part 2: Tolerances, dimensions and sectional properties

SS 503

Cold formed welded steel structural hollow sections

Part 1 : Technical delivery requirements

Part 2 : Tolerances, dimensions and sectional properties

Other Standards

ANSI/AWS

Structural welding code. Steel

D1.1-02

ASTM E165

Standard test method for liquid penetrant examination

ASTM E709

Standard guide for magnetic particle examination

ASTM E747

Controlling quality of radiographic testing using wire penetrameters

BS EN ISO 898-

Mechanical properties of fasteners made of carbon steel and alloy steel.

1

Bolts, screws and studs

BS EN ISO 1461

Hot dip galvanised coatings on fabricated iron and steel articles. Specifications and test methods

NPQS C5-10 Structural Steelwork

BS EN 10024

Hot rolled taper flange I sections. Tolerances on shape and dimensions

BS EN 10025

Hot rolled products of non-alloy structural steels. Technical delivery conditions

BS EN 10029

Tolerances on dimensions, shape and mass for hot rolled steel plates 3mm thick or above

BS EN 10051

Specification for continuously hot-rolled uncoated plate, sheet and strip of non-alloy and alloy steels. Tolerances on dimensions and shape

BS EN 10113

Hot-rolled products in weldable fine grain structural steels

Part 1: General delivery conditions

Part 2: Delivery conditions for normalised/ normalised rolled steels

Part 3: Delivery conditions for thermomechanical rolled steels

BS EN 10137

Plates and wide flats made of high yield strength structural steel in the quenched and tempered or precipitation hardened conditions

Part 1: General delivery conditions

Part 2: Delivery conditions for quenched and tempered steels

Part 3: Delivery condition for precipitation-hardened steels

BS EN 10155

Structural steels with improved atmospheric corrosion resistance. Technical delivery conditions

BS EN 10163

Specification for delivery requirement for surface condition of hot rolled steel plates, wide flats and sections

Part 1: General requirements

Part 2: Plates and wide flats

Part 3: Sections

BS EN 10210

Hot finished structural hollow sections of non-alloy and fine grain structural steels

Part 1: Technical delivery requirements

Part 2: Tolerances, dimensions and sectional properties

BS EN 10219

Cold formed welded structural hollow sections of non-alloy and fine grain steels

BS EN 10279

Hot rolled steel channels. Tolerances on shape, dimension and mass

BS EN 10034

Structural steel I and H section. Tolerance on shape and dimensions

BS EN 10055

Hot rolled steel equal flange tees with radiused root and toes. Dimensions and tolerances on shape and dimensions.

BS EN 10056-1

Structural steel equal and unequal leg angles. Dimensions

BS EN 10056-2

Specification for structural steel equal and unequal leg angles. Tolerances on shape and dimensions

BS 4-1

Structural steel sections. Specification for hot rolled sections

BS 2583

Podger spanners

BS 3692:

ISO metric precision hexagon bolts, screws and nuts – specification

BS 4190

ISO metric black hexagon bolts, screws and nuts – specification

BS 4320

Metal washers for general engineering purposes

NPQS C5-10 Structural Steelwork

BS 4395

High strength friction grip bolts and associated nuts and washers for structural engineering (metric series)

BS 4429

Specification for rigging screws and turnbuckles for general engineering lifting purposes and pipe hanger applications

BS 4604

Use of high strength friction grip bolts in structural steelwork (metric series)

BS 4921

Specification for sherardised coatings on iron and steel

BS 4933

ISO metric black cup and countersunk head bolts and screws with hexagon nuts

BS 5531

Code of practice for safety in erecting structural frames

BS 5950

Structural use of steelwork in building

Part 1: Code of practice for design. Rolled and welded sections

Part 2: Specification for materials, fabrication and erection. Rolled and welded sections

Part 4: Code of practice for design of floors with profiled steel sheeting

BS 7079

Preparation of steel substrates before application of paints and related products.

Part A1: Visual assessment of surface cleanliness

BS 7419

Specification for holding down bolts

BS 7644

Direct tension indicators.

Part 1: Specification for compressible washers

Part 2: Specification for nut face and bolt face washers

BS 7668

Weldable structural steels. Hot finished structural hollow sections in weather resistant steels

In the event that the Standards or Codes are partially superseded or become obsolete, refer to the latest edition or the approved substitution for the relevant clauses.

1.3.2 Technical Reference

When carrying out the works, take guidance from the following technical reference:

a. UK’s National Structural Steelwork Specification (NSSS), 4 th Edition, 2002.

1.4 Trade Preambles

1.4.1

Contractor’s Submissions and Proposals

1.4.1.1

Connection Design

Develop the connection design when required as indicated in the PSD.

Development of the design of connections is *required / not required.

Engage a PE (civil) to develop the design of the connections based on the structural design drawings.

1.4.1.2 Temporary Works

Engage a PE to plan, design and supervise any necessary temporary supports to ensure the structural steelwork is stable throughout the construction, paying attention to the safe erection of structural steelwork in accordance with BS 5531.

NPQS C5-10 Structural Steelwork

1.4.2 Shop Drawings

Engage qualified and experienced personnel to prepare coordinated shop drawings for the fabrication and erection of the steelwork.

1.4.3

Qualifications

1.4.3.1

Steel Fabricators

Engage steel fabricators who are accredited under the Structural Steel Fabricators Accreditation Scheme of the Singapore Structural Steel Society for the fabrication works.

Refer to the PSD for the required grade of the fabricator.

The required grade of steel fabricator is

1.4.3.2 Supervisors

All structural steelwork and associated works are to be undertaken and supervised by appropriately experienced personnel. Provide evidence of personnel’s past experience and certificate to the SO for acceptance prior to commencement of the Works.

1.4.3.3 Welder Qualification

Submit evidence of welders’ competence to the to undertake the specified work.

The welders are to be tested to meet the requirements of ANSI/AWS D1.1 Section 4 Part C. The welder’s test is to be conducted and certificates are to be issued by the Independent Inspection and Testing Agency.

1.4.4 Quality Control Plan

Submit and work to a quality control plan as agreed with the SO. Refer to the General Requirements section, clause 1.4.10 for guidance.

1.4.5 Accredited Laboratory

Engage a laboratory accepted by the SO and accredited under the Singapore Laboratory Accreditation Scheme (SINGLAS) to carry out tests and checks as required by this Specification, including all on site weld tests where applicable.

1.4.6 Independent Inspection and Testing Agency (ITA)

Appoint an independent Inspection and Testing Agency (ITA) when required as indicated in the PSD.

Appointment of an accredited inspection body is *required / not required.

When required, the scope of service of the ITA shall be as follows:

S/N

Description

Tick where

applicable

1.

Review the quality manuals, inspection & test plans

 

2.

Review fabrication and erection procedures

 

3.

Review of welding procedure specification, procedure qualification records, welder and welding operator qualification records.

 

4.

Pre-inspection meeting and audit of fabricator facilities/plants

 

NPQS C5-10 Structural Steelwork

5.

Review of material test certificates/records, verify or inspect materials and witness pre-treatment processes, if any

6.

Witness cutting/edge joint preparations, verify joint geometry and inspect fit-up condition

7.

Verify that welding processes are carried out in accordance with the approved welding procedures, codes/standards and relevant documents

8.

Perform visual inspection and verify dimensional records

9.

Select weld joints for testing & witness non-destructive testing and assess all results

10.

Witness blasting & galvanising processes

11.

Inspect painting and galvanising works

12.

Identify & verify completed structural members and witness the handling of these members onto lorry/truck for delivery to site

13.

Inspect delivered structural members for damage due to handling and transportation

14.

Inspect the assembly of structural members at erection site prior to welding

15.

Verify all welding procedure and welder qualification records at site

16.

Witness procedure trial of stud welding process

17.

Inspect all welds & bolt tightening

18.

Select weld for testing and witness site NDT

19

Inspect all remaining site painting and witness repairing of all protective treatment works

20.

Witness fireproofing mock-up test as well as laboratory tests

21.

Witness and inspect the application of fireproofing works

22.

Final inspection of all structural members

23.

Review all documents and records including but not limited to the following:

- Dimensional

- Procedures

- Testing

Alternatively, the SO may engage the ITA separately.

In either of the above cases, make available to the ITA the following:

a. All requested documentation and a detailed programme to allow the ITA to discharge its duties and to witness significant stages in the fabrication and erection process.

b. Any instruments or other equipment required checking the accuracy and quality of the works.

NPQS C5-10 Structural Steelwork

1.5

Definitions

a. Design

Drawings showing the dimensioned layout of the steel structure with the size and material grades of all members, the forces to be developed in their connections and any cambers etc, from which shop drawings are made.

Drawings

b. Shop

Drawings showing all necessary information to fabricate the structural steelwork, including the piece markings with the location in the structure.

Drawings

c. Reaming

Forming, shaping, tapering, or enlarging a hole with a reamer.

d. Faying

Surfaces which are tightly or closely fitted.

Surfaces

NPQS C5-10 Structural Steelwork

2.

PERFORMANCE REQUIREMENTS

2.1

Design Brief

When carrying out design as described in Clause 1.4.1, ensure the design conforms to the requirements of BS 5950 or other design codes as indicated in the PSD. Design the connections based on forces given in the design drawings.

When carrying out design as described in Clause 1.4.1, ensure the design conforms to the requirements of

2.2

Loading During Construction

Ensure that the steelwork is adequately braced or restrained to withstand all loadings liable to be encountered during construction without inducing excessive stresses, deflections or distortion in the structure.

NPQS C5-10 Structural Steelwork

3.

MATERIALS

3.1

Steel Sections/Elements

3.1.1 Material Qualities

Material qualities, dimensions and tolerances are to comply with the appropriate standard as tabulated below:

MATERIAL, DIMENSION AND TOLERANCE STANDARDS

 
 

Material Qualities

     

Form

Non-alloy

Fine

Q&T

Weathering

Dimensions

Tolerances

steels

grain

steels

steels

steels

Universal

       

BS 4 -1

BS EN

Beams &

10034

Columns

Joists

BS 4 -1

BS EN

10024

Channels

BS 4 -1

BS EN

10279

Rolled

(4)

(4)

Asymmetric

Beams

BS EN

BS EN

BS EN

BS EN

Angles

10025 (1)

10113

10137-2

10155

BS EN 10056-1

BS EN

(2)

10056-2

Rolled Tees

BS EN 10055

BS EN

10055

Split Tees

BS 4 - 1

As UB & UC

Plates

-

BS EN

(Reversing Mill)

10029

Plates (Cut from Coil)

-

BS EN

10051

Bars and Rods

- -

 

Wide Flats (3)

- -

 

Hollow Sections

SS 470: Part 1 (BS EN 10210-1)

-

BS 7668

SS 470: Part 2 (BS EN 10210-2)

 

(Hot-Finished) (5)

Hollow Sections

SS 503: Part 1 (BS EN 10219-1)

-

-

SS 503: Part 2 (BS EN 10219-2 (4) )

 

(Cold-Formed) (5)

Turnbuckles

BS 4429

     

3.1.2 Mill Certificates

All steel elements are to have the manufacturer’s mill test certificates indicating compliance with the specified codes.

3.1.3

Surface Condition

3.1.3.1

General Condition

Steel for fabrication is not to be more heavily pitted or rusted than Grade C of BS 7079 Part A1.

3.1.3.2 Rectification of Surface Defects

For hot rolled plates and wide flats, if there are surface imperfections and defects as classified in BS EN 10163-2 Clause 4 (Requirements) revealed during surface preparation, rectify the surface in accordance to BS EN 10163-2 Clause 5 (Repair Procedures).

NPQS C5-10 Structural Steelwork

For hot rolled sections, if there are surface imperfections and defects as classified in BS EN 10163-3 Clause 4 (Requirements) revealed during surface preparation, rectify the surface in accordance to BS EN 10163-3 Clause 5 (Repair Procedures).

For hot rolled hollow sections, rectify the surface imperfections and defects revealed during surface preparation in accordance to BS EN 10210-1 Clause 6.8 (Surface Condition).

3.2 Welding Consumables

Welding consumables for metal arc welding are to comply with ANSI/AWS D1.1 Clause 5.3 (Welding Consumables and Electrode Requirements).

Ensure compatibility between welding consumables and parent materials used for the

steelwork.

3.3 Fasteners

3.3.1 Ordinary Bolt Assemblies

Ordinary bolts (full and part threaded length) are to comply with BS 4190 for all

grades.

Ordinary nuts are to comply with BS 4190 (grade 4 for grade 4.6, 8 for 8.8 and 10 for

10.9).

For galvanised or sherardised bolts use class 10 nuts for 8.8 bolts and class 12 nuts for 10.9 bolts.

Black steel washers are to comply with BS 4320 Section 2.

3.3.2

Countersunk Bolt Assemblies

3.3.2.1

Bolts

Comply with BS 4933 for grade 4.6 (cup headed bolts and 90° countersunk head bolts).

Comply with BS 4933 (dimensions) and BS EN ISO 898-1 (material) for grade 8.8

bolts.

3.3.2.2

Nuts

Comply with BS 4190 (grade 4) for grade 4.6 bolts.

Comply with BS 3692 (grade 8) for grade 8.8 bolts.

3.3.2.3 Washers

Ordinary steel washers (normal diameter series) are to comply with BS 4320 Section

2.

3.3.3

High Strength Friction Grip Fasteners

Bolts, nuts and washers are to comply with:

a. BS 4395-1 for general grade bolts

b. BS 4395-2 for higher grade bolts

washers are to comply with: a. BS 4395-1 for general grade bolts b. BS 4395-2 for

NPQS C5-10 Structural Steelwork

3.3.4 Lock Nuts for Bolt Assemblies

Comply with BS 3692 or BS 4190 as appropriate.

3.3.5

Holding Down Assemblies

3.3.5.1

Bolts

Comply with BS 7419 for grades 4.6 and 8.8.

3.3.5.2 Nuts

Comply with BS 4190:

Grade 4 for grade 4.6 bolts.

Grade 8 for grade 8.8 bolts.

Class 10 for galvanised or sherardised grade 8.8 bolts.

3.3.5.3 Washers

Comply with BS 4320 Section 2 (normal diameter series) for bolts grades 4.6 and 8.8.

3.3.6 Shear Studs

Proprietary headed studs are to have the following properties:

a. Minimum yield strength of 350 N/mm 2

b. Minimum ultimate tensile strength of 450 N/mm 2

c. Elongation of 15% on a gauge length of 5.65 A, where A = area of test specimen

d. Diameter and nominal length as noted on the drawings

3.4 Profiled Steel Decking

Comply with BS 5950-4 Clause 3.1 unless otherwise agreed.

3.5 Protective Finishes

3.5.1 Galvanising Materials

Comply with BS EN ISO 1461.

3.5.2 Sherardised Coatings

Comply with BS 4921.

3.5.3 Metallic Blast Cleaning Abrasives

Comply with BS 7079-E2 for chilled iron grit.

Comply with BS 7079-RE3 for cast steel grit.

3.5.4 Surface Coatings

Refer to Section C5-20, clause 3.0 for all paints and other coatings.

3.6 Grout

Grout is to comply with BS 5950-2 Section 2.5.

Grout around anchor bolts under base plates and between steel plates and concrete surface is to have a minimum compressive strength at 28 days of 40 N/mm 2 .

NPQS C5-10 Structural Steelwork

Proprietary grouts are not to contain high alumina cement.

NPQS C5-10 Structural Steelwork

4.

WORKMANSHIP

4.1

General

4.1.1

Traceability

All steel elements are to be identified and traceable to the manufacturer’s material/mill test certificates.

4.1.2

Marking

Mark all pieces so that they can be identified at all stages of fabrication.

Mark completed components in locations that will not be covered up by other material after erection to avoid confusion.

Hard stamping may be used other than where specified in the PSD.

Hard stamping may be used other than at the following areas:

a.

b.

Keep areas of steelwork free of all markings where so required on the Drawings.

4.2

Storage and Handling

Prepare and comply with proper storage and handling procedures in approved method statement to ensure achievement of the desired quality and to minimise damage to the steelwork.

4.2.1

Holding Areas

Lay steel in separate holding areas and keep clean.

4.2.2

Storage

Adequately support steel clear of the ground. Keep clean and do not allow water to accumulate on components. Protect steel against corrosion.

Ensure individual piece markings are visible when members are stacked.

4.2.3

Handling

Plan and carry out bundling, packing, handling and transport in a manner designed to prevent permanent distortion to the steelwork and minimise damage to any protective coating.

4.2.4

Storage and Drying of Welding Consumables

Store and protect welding consumables that have been removed from the original package so that the welding properties are not affected.

Carry out drying or re-baking, where necessary, in accordance with the manufacturer’s recommendations.

4.3

Fabrication

Prepare and comply with proper fabrication procedures to SO’s acceptance, to ensure achievement of the desired quality.

NPQS C5-10 Structural Steelwork

4.3.1 Cutting

Comply with BS 5950-2 Clause 3.3 (Cutting).

Cut and shape steel by sawing, shearing, cropping, nibbling, plasma or laser cutting and thermal or flame cutting.

Thermal cutting are not permitted at the areas indicated in the PSD.

Thermal cutting are not permitted at the following areas:

a.

b.

4.3.1.1

Hand Flame Cutting

Use only where it is impractical to use machine flame cutting.

4.3.1.2 Flame Cut Edges

Flame-cut edges that are free from significant irregularities require no further treatment other than dressing as specified in 4.3.3(Dressing).

4.3.2 Holing

Comply with BS 5950-2 Clause 3.4 (Holing).

4.3.2.1 Forming

Drill, punch, plasma or laser cut and thermal or flame cut round holes for fasteners.

Thermal holing or full size hole punching are not permitted at the areas indicated in the PSD.

Thermal holing or full size hole punching are not permitted at the following areas:

a.

b.

4.3.2.2

Matching

Ensure all matching holes are formed such that fasteners can be inserted freely through the assembled members at right angles to the contact faces.

Drifting to align holes may be used provided it neither enlarges nor distorts the holes.

4.3.2.3 Drilling through Multiple Thickness

Tightly clamp the separate parts before drilling and remove any burrs after separating the parts.

4.3.2.4 Punching Full Size

Punching of full size holes is permitted when all the following conditions are satisfied:

a. The tolerance on distortion of the punched hole does not exceed that specified;

b. The holes are free of burrs which would prevent solid seating of the parts when tightened;

c. The thickness of the material is not greater than 30mm, nor greater than the diameter of the hole being punched;

NPQS C5-10 Structural Steelwork

d. In spliced connections when the holes in mating surfaces are punched in the same direction and the splice plates marked to show the assembly faces, if packed separately.

4.3.2.5 Punching and Reaming

When the conditions in 4.3.2.4 is not satisfied, punching is still permitted provided that the holes are punched at least 2mm less in diameter than the required size and the holes are then reamed to the full diameter after assembly.

4.3.3

Dressing

4.3.3.1

Removal of Burrs

Dress cut edges or holes to remove dross, burrs, irregularities and protruding edges.

If holes are drilled through components that are clamped together not intended to be separated after drilling, removal of burrs is not required.

4.3.3.2 Dressing of Sharp Edges

Dress all sharp edges.

A 90° rolled, sheared or machined cut edge requires no further treatment.

4.3.4 Curving and Straightening

Curve or straighten components during fabrication using mechanical means or the local application of heat.

4.3.4.1 Heating

Control the temperature carefully and do not let the temperature exceed 650°C.

4.3.4.2 Inspection

After the process is complete, visually inspect all welds within the area of curving or straightening. Carry out non-destructive testing of welds, where directed.

4.4

Bolting

4.4.1

Hole Sizes for Bolting

4.4.1.1

Ordinary and HSFG Bolts

a. For bolts 24mm diameter, hole sizes are to be bolt diameter +2mm.

b. For bolts > 24mm diameter, hole sizes are to be bolt diameter +3mm.

4.4.1.2 Holding Down Bolts

Hole sizes are to be bolt diameter +6mm with sufficient clearance to ensure the bolt can be accommodated through the base plate when adjusted.

4.4.1.3 Fitted Bolts

Clearance of bolt in hole is not to exceed 0.3mm.

4.4.2

Ordinary Bolted Assemblies

4.4.2.1

Make-up of Bolt Assemblies

Refer to Clause 3.3.1(Ordinary Bolt Assemblies) for strength grade combination of

bolt/nuts/washers.

NPQS C5-10 Structural Steelwork

4.4.2.2 Condition of Bolts

Bolt assemblies are to be in such condition immediately before installation that the nut turns freely on the bolt.

4.4.2.3 Differing Grades of Bolts

Unless otherwise agreed by the SO, do not use different bolt grades of the same diameter in the same structure.

bolt grades of the same diameter in the same structure. 4.4.2.4 Bolt Length The length of

4.4.2.4 Bolt Length

The length of bolt is to be such that at least one clear thread shows above the nut after tightening, and at least one thread plus the thread run out is clear between the nut and the unthreaded shank of the bolt.

4.4.2.5 Washers

Use at least one washer placed under the nut or bolt head being rotated in each bolt assembly where the rotation might damage the surface protective treatment on the members being connected. Use a plate or heavy duty washer under the head and nut where the members being connected have oversize or slotted holes.

4.4.2.6 Taper Washers

Place under bolt heads and nuts bearing on surfaces sloping 3 ° or more from a plane at right angles to the bolt axis.

4.4.2.7 Galvanised Nuts

Check after galvanizing to ensure free running on the bolt. Re-tap nuts, if necessary, to ensure satisfactory tightening.

4.4.2.8 Tightening

Use power tools or by hand using appropriate spanners to BS 2583.

4.4.2.9 Locking of Nuts

Secure nuts used in connections subject to vibration or reversal of stresses to prevent loosening. If not specified on the drawings, include the proposed method in the erection details.

4.4.2.10 Fit-up Using Ordinary Bolt Assemblies

Draw connected parts firmly together. If there is a remaining gap more than 2mm, which may affect the integrity of the joint, take the joint apart and insert a pack of the same steel material.

4.4.2.11 Reaming

Reaming may be used where the connection design allows the use of larger diameter holes and bolts in cases where drifting would distort the steelwork.

4.4.3

High Strength Friction Grip Fasteners

4.4.3.1

Make-up of Bolt Assemblies

Refer to Clause 3.3.3(High Strength Friction Grip Fasteners) for strength grade combination of bolt/nuts/washers.

Place the hardened washer under the nut or head being turned.

NPQS C5-10 Structural Steelwork

4.4.3.2 Tightening

Use high strength friction grip bolts in compliance with BS 4604-1 or 2.

Use the torque control method, the part-turn method or direct tension indicators in accordance with the manufacturer’s recommendations for tightening in compliance with BS 4604-1.

4.4.3.3 Calibration of Torque Equipment

Calibrate torque devices at least once each shift.

Recalibrate where necessary in accordance with BS 4604.

4.4.3.4 Discarded Bolt Assemblies

If after tightening, a bolt or nut is slackened off for any reason, discard the complete bolt assembly and do not re-use in the Works.

4.4.3.5 Fit-up Using High Strength Friction Grip Fasteners

Draw connected parts firmly together with all bolts partially tightened. If there is a remaining gap, take the joint apart and insert a pack of the same steel material before continuing tightening.

4.4.3.6 Reaming

Reaming may be used where the connection design allows the use of larger bolts in cases where drifting would distort the steelwork.

Demonstrate by calculation that the connection is adequate for the specified forces.

4.4.3.7 Faying Surfaces for HSFG Fasteners

Remove all mill-scale from the faying surfaces of friction grip joints.

Ensure the faying surfaces of friction grip joints are free of distortion, deformities or contaminants, which may reduce the slip factor below the design value.

4.4.4 Slotted Holes Bolts

Where slotted holes are provided for movement connections ensure the joint is free to move.

4.4.5 Holes in Hollow Sections

Seal bolt holes and vent holes in hollow sections to prevent the ingress of moisture.

If not specified on the design drawings, show the proposed method on the shop drawings.

4.5

Welding

4.5.1

Welding Processes

Processes for Shielded metal arc welding (SMAW), submerged arc welding (SAW), gas metal arc welding (GMAW) except GMAW-S, short circuiting transfer and flux cored arc welding (FCAW) which conform to all of the requirements of ANSI/AWS D1.1 Section 3 are deemed as pre-qualified and accepted for use without performing the Welding Procedure Specifications (WPS) Qualification Tests.

Gas tungsten arc welding (GTAW), electro-slag welding (ESW) or electro-gas welding (EGW) and gas metal arc welding - short circuiting transfer (GMAW-S) are to conform to all of the requirements of ANSI/AWS D1.1 Section 4.

NPQS C5-10 Structural Steelwork

4.5.2 Welding Supervisor

Carry out welding under the direction of a welding supervisor with appropriate

qualifications.

4.5.3

Welding Procedures Specifications

4.5.3.1

Preparation

Prepare Written Welding Procedure Specification (WPS) in accordance with ANSI/AWS D1.1 Section 4 Part B for acceptance by the Independent Inspection and Testing Agency.

4.5.3.2 Procedure Tests

All procedure tests conducted are to be witnessed by the Independent Inspection and Testing Agency.

4.5.3.3 Availability of Welding Procedure Specifications

Make WPS available to the welder, the SO and the Independent Inspection and Testing Agency prior to the commencement of the works.

4.5.3.4 Inspection and test plans

Submit all inspection and test plans for SO’s acceptance prior to carrying out welding

works.

4.5.4

Assembly

4.5.4.1

Fit-up

Fit up joints to the dimensional accuracy in accordance with the following:

a. ANSI/AWS D1.1 Clause 3.9 (Fillet Weld Requirement) for Fillet Welding

b. ANSI/AWS D1.1 Clause 3.11 (Common Requirements of Partial and Complete Joint Penetration Groove Welds) and Clause 3.12 (Partial Joint Penetration Requirements) for Partial Penetration Butt Welding.

c. ANSI/AWS D1.1 Clause 3.11 (Common Requirements of Partial and Complete Joint Penetration Groove Welds and Clause 3.13 (Complete Joint Penetration Requirements) for Partial Penetration Butt Welding.

4.5.4.2 Temporary Welds and Tack Welds

Temporary welds are subject to the same welding procedure requirements as the final welds. Remove the temporary welds unless otherwise agreed by the SO. Make flush the surface with the original surface after the removal.

Tack welds are subject to the same quality requirements as the final welds, with the following exceptions:

a. Preheat is not mandatory for single-pass tack welds which are re-melted and incorporated into continuous submerged arc welds.

b. Discontinuities, such as undercut, unfilled craters and porosity need not be removed before the final submerged arc welding.

c. Tack welds, which are incorporated into the final weld, are to be made with electrodes meeting the requirements of the final welds and are to be cleaned thoroughly. Multiple-pass tack welds are to have cascaded ends.

NPQS C5-10 Structural Steelwork

Remove tack welds, which are not incorporated into the final weld, unless otherwise agreed by the SO.

4.5.4.3 Control of Distortion and Shrinkage

Procedure and sequence of welding is to be in accordance with ANSI/AWS D1.1 Clause 5.21 to minimise distortion and shrinkage.

4.5.4.4 Temporary Attachments

Welding of temporary attachments required for fabrication or erection is to be carried out in accordance with the requirements for permanent welds.

Remove after use where required by flame cutting or gouging at a point not less than 3mm from the surface of the parent metal.

Grind flush and inspect the area visually.

Where the parent metal is more than 20mm thick, check by magnetic particle testing method inspection using the acceptance criteria stipulated in Clause Error! Reference source not found.(Non-Destructive Testing of Welds).

Do not remove temporary attachments by hammering.

4.5.5

Shear Stud Welding

4.5.5.1

Method

Fix shear studs in accordance with the manufacturer’s recommendations for materials, procedures and equipment.

4.5.5.2 Welding Procedure Trial

Where required, carry out welding procedure trial of studs to demonstrate the suitability of the proposed welding system and equipment before commencement of the work.

The trial is to use the materials and procedures proposed for the works. Test a minimum of ten studs in the trial.

During the work, at the commencement of each shift, each welder is to undertake a minimum of two trial welds.

4.5.5.3 Visual Inspection

Visually inspect all studs. They are to exhibit full 360 degree ‘flash’ with no evidence of undercut into the stud base.

4.5.5.4 Bend Test

Subject studs to bend tests at locations agreed with the SO.

Test at least 5% of studs and not less than two per beam.

Bend the head of the stud by striking the head of the stud to an angle of approximately 30° from their original axis with a hammer. Under this test the weld is to show no visible signs of cracking or lack of fusion.

Do not straighten any studs so tested.

4.5.5.5 Defective Studs

Replace any studs with defective welding and re-test as above.

Where defective studs are removed check the surface as specified in 4.5.5.3 above.

NPQS C5-10 Structural Steelwork

4.5.6 Removal of Slag

Remove slag by light hammering, wire brushing or other means that do not deform the surface of the weld.

4.6 Permitted Deviations (PDs) of Fabrication

4.6.1

PDs in Rolled Components After Fabrication

4.6.1.1

Cross Section After Fabrication

In accordance with the appropriate standards given in clause 3.1.1(Material Qualities)

4.6.1.2 Squareness of Ends not Prepared for Bearing

PD = D/300, where D is the depth of the section.

D
D

= D/300

Plan or Elevation of End

4.6.1.3 Squareness of Ends Prepared for Bearing

PD = D/1000, where D is the depth of the section and the deviation is measured relative to the longitudinal axis of the member.

= D/1000 90° D Plan or Elevation
= D/1000
90°
D
Plan or Elevation

4.6.1.4 Straightness

PD of a member from a straight line drawn between adjacent points of subsequent effective lateral restraint = 3mm or L/1000, whichever is greater, where L is the distance between restraints.

L
L

= L/1000 or 3mm whichever is the greater

4.6.1.5 Camber

PD from specified or proposed camber at mid-length = 6mm or L/1000, whichever is greater, where L is the length of the member.

NPQS C5-10 Structural Steelwork

Deviation L Deviation = L/1000 or 6mm whichever is the greater
Deviation
L
Deviation = L/1000 or 6mm
whichever is the greater

4.6.1.6 Length

PD after cutting, measured on the centre line of the section or on the corner of angles = 2mm.

L ± = 2mm
L ±
= 2mm

4.6.2

PDs of Fabricated Components

4.6.2.1

Position of Fittings

PD from the intended position for fittings and components whose location is critical to the force path = 3mm.

= 3mm
= 3mm

4.6.2.2 Position of Holes

PD from the intended position of hole or group of holes = 2mm.

from the intended position of hole or group of holes = 2mm. = 2mm 4.6.2.3 Punched

= 2mm

4.6.2.3 Punched Holes

Distortion caused by a punched hole is not to exceed D/10 or 1mm, whichever is greater, where D is the nominal hole diameter.

NPQS C5-10 Structural Steelwork

D

NPQS C5-10 Structural Steelwork D = D/10 or 1mm whichever is the greater 4.6.2.4 Sheared or

= D/10 or 1mm whichever is the greater

4.6.2.4 Sheared or Cropped Edges of Plates or Angles

Deviation from a 90° edge is not to exceed t/10 where t = plate thickness.

t = t/10
t
= t/10

4.6.2.5 Flatness

Gaps in joints that depend on contact bearing when assembled during fabrication are not to exceed 0.75mm and are to be less than 0.25mm over 50% of the length of contact of the section.

=0 75mm 4.6.3 PDs in Plate Girder Sections 4.6.3.1 Depth
=0 75mm
4.6.3
PDs in Plate Girder Sections
4.6.3.1
Depth

PD measured on centre line = ± 4mm.

D ±
D ±

= 4mm

4.6.3.2 Flange Width

For flange width B < 300mm, PD = ±3mm.

For flange width B300mm, PD = ±5mm.

NPQS C5-10 Structural Steelwork

B ± w B or w = B or w = B ± n
B
±
w
B
or
w
=
B
or
w
=
B
±
n

B

n

< 300

3mm

B

n

> _ 300

5mm

4.6.3.3 Squareness of Sections

For flange width B, PD on out of squareness = B/100 or 3mm, whichever is greater.

B Flange width

= B/100 or 3mm, whichever is greater. B Flange width = B / 100 or 3mm

= B / 100 or 3mm whichever is the greater

4.6.3.4 Web Eccentricity

PD on intended position of web from one edge of flange = ± 5mm.

b = 5mm ± 4.6.3.5 Flanges
b
= 5mm
±
4.6.3.5 Flanges

For flange width B, PD on out of flatness = B/100 or 3mm, whichever is greater.

B Flange width
B Flange width

= B/100 or 3mm whichever is the greater

4.6.3.6 Top Flange of Crane Girder

PD on out of flatness where rail seats = 1mm.

w = Rail width + 20mm w w
w = Rail width + 20mm
w
w

= 1mm

4.6.3.7 Length

PD on length on centre line = ± 3mm.

NPQS C5-10 Structural Steelwork

L ± = 3mm 4.6.3.8 Flange Straightness
L ±
= 3mm
4.6.3.8 Flange Straightness

PD on straightness of individual flanges = L/1000 or 3mm, whichever is greater, where L is length.

L
L

= L/1000 or 3mm whichever is the greater

4.6.3.9 Curve or Camber

PD on intended curve or camber at mid-length of curved portion = L/1000 or 6mm, whichever is greater, where L is length and deviation is measured with web horizontal.

Deviation L Deviation = L/1000 or 6mm h hi i th t
Deviation
L
Deviation = L/1000 or 6mm
h
hi
i
th
t

4.6.3.10 Web Distortion

PD on distortion on web depth (or gauge length) = d/150 or 3mm, whichever is greater, where d is depth of web.

d

gauge length = web depth
gauge
length = web depth

= d/150 or 3mm

4.6.3.11 Cross Section at Bearings

PD on squareness of flanges to web = D/300 or 3mm, whichever is greater, where D is depth of section.

D
D

= D/300 or 3mm whichever is the greater

4.6.3.12 Web Stiffeners

PD on straightness of stiffener out of plane with web after welding = d/500 or 3mm, whichever is greater, where d is depth of stiffener.

NPQS C5-10 Structural Steelwork

d
d

= d/500 or 3mm whichever is the greater

PD on straightness of stiffener in plane with web after welding = d/250 or 3mm, whichever is greater, where d is depth of stiffener.

d
d

= d/250 or 3mm whichever is the greater

4.6.4

PDs in Box Sections

4.6.4.1

Plate Widths

For B f or B w < 300mm, PD = ±3mm, where B f , B w are flange width and web depth respectively.

For B f or B w 300mm, PD = ± 5mm.

B

B

f

f

B ± f B ± w or B < 300 w = 3mm or B
B
±
f
B
±
w
or
B
< 300
w
=
3mm
or
B
w > _ 300

= 5mm

4.6.4.2 Squareness

PD on squareness measured at diaphragm positions = D/300, where D is section depth.

= D/300 D 4.6.4.3 Plate Distortion
= D/300
D
4.6.4.3 Plate Distortion

PD on distortion on width or gauge length = w/150 or 3mm, whichever is the greater, where w is depth of web.

NPQS C5-10 Structural Steelwork

gauge length = width, w

w

NPQS C5-10 Structural Steelwork gauge length = width, w w = w/150 or 3mm whichever is

= w/150 or 3mm whichever is the greater

4.6.4.4 Web or Flange Straightness

PD on straightness of individual web or flanges = L/1000 or 3mm, whichever is the greater, where L is full length.

L
L

= L / 1000 or 3mm whichever is the greater

4.6.4.5 Web Stiffeners

PD on straightness in plane with plate after welding = d/500 or 3mm, whichever is the greater, where d is depth of web.

d
d

= d / 500 or 3mm whichever is the greater

PD on straightness out of plane to plate after welding = d/250 or 3mm, whichever is the greater, where d is depth of web.

d
d

= d / 250 or 3mm whichever is the greater

4.6.4.6 Length

PD on length measured on centre line = ± 3mm.

L ± = 3mm
L ±
= 3mm

NPQS C5-10 Structural Steelwork

4.6.4.7 Curve or Camber

PD on deviation from intended curve or camber at mid-length of curved portion when measured with the un-cambered side horizontal = L/1000 or 6mm, whichever is the greater, where L is length of the curved portion.

Deviation L Deviation = L / 1000 or 6mm whichever is the greater 4.7 Erection
Deviation
L
Deviation = L / 1000 or 6mm
whichever is the greater
4.7
Erection
4.7.1
General

Prepare and comply with proper erection procedures to SO’s acceptance, to ensure achievement of the desired quality and safety, paying attention to site conditions, constraints and restrictions.

4.7.2 Erection Loads

Ensure that the structure is not overloaded by stacking of materials.

4.7.3 Temporary Supports

Any temporary supports used may be removed after the structure has been lined, levelled and plumbed, provided sufficient components have been erected and secured to ensure the overall structure remains stable under the worst anticipated conditions of loading.

4.7.4 Alignment

Align each part of the structure as soon as practicable after erection. Do not make permanent connections between members until the structure has been sufficiently aligned, levelled, plumbed and temporarily connected so that members will not be displaced during subsequent erection or alignment of the remainder of the structure.

4.7.5 Temperature Adjustment

Take due account of the effects of temperature on the structure and measuring equipment when measurements are made for setting-out and erection, and for dimensional checks carried out subsequently.

Adopt 30°C as the reference temperature unless otherwise agreed .

4.7.6 Site Welding

Carry out site welding only by agreement with the SO or as shown on the design drawings.

Carry out all site welding in accordance with clause 4.5(Welding) above.

Do not carry out site welding in inclement weather unless adequate weather protection is provided for welders and materials.

NPQS C5-10 Structural Steelwork

4.7.7 Foundation Bolts

Hold foundation bolts firmly in position during all setting-in operations.

Protect bolts, threads and nuts against damage, corrosion and contamination at all stages of construction.

Keep pockets formed around foundation bolts clean and free from all extraneous

matter.

Use templates to set in the holding-down bolts.

4.7.8 Packs and Wedges

Plumb and level columns using steel packs and wedges of adequate strength and stiffness, and not larger than necessary for the purpose.

Where packings are to be left in position and subsequently grouted, place them such that they are totally enclosed by the grout.

4.7.9 Grouting

Carry out grouting in accordance with BS 5950-2 Clause 6.3.

Do not carry out grouting under column base plates until a sufficient portion of the structure has been aligned, levelled, plumbed and adequately braced.

Immediately before grouting, clean the space under the column base plates to be free of all extraneous matter.

Prepare, mix and place proprietary grout in accordance with the manufacturer’s

recommendations.

4.7.10 Profiled Steel Decking

Install in accordance with manufacturer’s recommendations, including the provision of edge trims, temporary supports, lapping, etc.

4.8 Permitted Deviations (PDs) in Erection

Erect steelwork within the PDs in the following clauses.

4.8.1 Receiving Structures and Connections

Ensure that structures by others to which the steelwork attaches is constructed within the anticipated PDs before commencing steel erection.

Where components and fixings are cast in by others ensure that they are also within the anticipated PDs before commencing steel erection.

Inspect for position and level in good time before the planned start of steelwork

erection.

In the event of any discrepancies found, notify the SO, propose and correct the

discrepancies.

4.8.2

PDs of Holding Down Bolts

4.8.2.1

Bolts or Bolt Groups with Allowance for Adjustment

a.

b. Minimum clearance:

Bolt level:

+25/-5mm.

25mm at top of concrete

NPQS C5-10 Structural Steelwork

c. Bolt centroid:

±10mm from specified position at top of concrete.

= ± 10 mm from specified position at top of concrete + 25 mm =
= ± 10 mm from specified position
at top of concrete
+ 25 mm
=
bolt level
- 5 mm
25 mm minimum
clearance at top
of concrete

4.8.2.2 Bolts or Bolt Groups with No Allowance for Adjustment

a.

b. Bolt centroid:

Bolt level:

+45/-5mm.

±3mm from specified position at top of concrete.

= ± 3 mm from specified position at top of concrete + 45 mm =
=
± 3 mm from specified position
at top of concrete
+
45 mm
=
bolt level
-
5 mm

4.8.2.3 Bolts or Bolt Groups Cast into Walls (No Allowance for Adjustment)

a. End of bolt: +45/-5mm. b. Bolt centroid: ±3mm position in plan and elevation. +
a. End of bolt:
+45/-5mm.
b. Bolt centroid:
±3mm position in plan and elevation.
+ 45 mm
=
bolt level
- 5 mm
= ± 3 mm
position in plan
and elevation

4.8.3 PD of Level of Base Plate

PD of level of column base plate = 5mm.

4.8.4

PDs of Erected Components

4.8.4.1

Position of Columns at Base

PD of section centreline from the specified position = 10mm.

PD of section centreline from the specified position = 10mm. = 10mm 4.8.4.2 Overall Plan Dimension

= 10mm

4.8.4.2 Overall Plan Dimension

PD on length or width = 20mm for L < 30m and [20 + 0.25 (L-30)] mm for L 30m, where L is the specified overall dimension in metres.

NPQS C5-10 Structural Steelwork

4.8.4.3 Plumb of Single Storey Columns

PD of top relative to base = ± h/600 or 5mm, whichever is greater, on main axes, excluding portal frame columns, where h is the storey height.

H = ± H/600 or 5 mm whichever is greater
H
= ± H/600 or 5 mm
whichever is greater

Max = ± 25mm

H

4.8.4.4 Plumb in Multi Storey Columns

PD in each storey of column = h/600 or 5mm, whichever is greater, where h is the storey height.

PD of column at top storey relative to specified position at base plate = 50mm maximum.

H h = storey height h h = ± h/600 or 5 mm whichever is
H
h = storey
height
h
h
= ± h/600 or 5 mm
whichever is greater
H
= 50mm maximum

4.8.4.5 Alignment of Adjacent Perimeter Columns

PD of one column relative to the next on a line parallel to the grid line = 10mm when measured at the base or splice level.

= 10 mm
= 10 mm

critical face of columns

4.8.4.6 Gap Between Bearing Surfaces

PD = (D/1000 +1) mm where D is the dimension along the bearing surface.

D = (D / 1000) + 1 mm D 4.8.4.7 Level of Beams
D
= (D / 1000) + 1 mm
D
4.8.4.7 Level of Beams

a. PD of two or more beams meeting at a column = ± 5mm.

NPQS C5-10 Structural Steelwork

Specified Level = ± 10mm
Specified
Level
= ± 10mm

b. PD on level of beam at its ends = 5mm.

= ± 5mm
= ± 5mm

c. PD on level of adjacent beams within a distance of 5m = ± 5mm.

= ± 5mm
= ± 5mm

d. PD from specified level of beam at supporting column = ± 10mm.

h

Floor Level Floor Level h<3m, = 5mm h<3m = h/600
Floor
Level
Floor
Level
h<3m,
= 5mm
h<3m
= h/600

e. PD of beam relative to adjacent beam above or below = 5mm for h < 3m and h/600 for h 3m, where h = storey height in m.

4.8.4.8 Plumb of Crane Gantry Columns

PD = ± H c /1000 or 5mm, whichever is greater to a maximum of ± 25mm.

H c = ± H c /1000 or 5mm
H
c
= ± H
c /1000 or 5mm

whichever is greater

Max = ± 25mm

4.8.4.9 Crane Gantries Gauge of Rail Tracks

PD from true gauge = ± 10mm.

NPQS C5-10 Structural Steelwork

G + H

= ± 10mmNPQS C5-10 Structural Steelwork G + H 4.8.4.10 Joints in Gantry Crane Rails a. PD on

4.8.4.10 Joints in Gantry Crane Rails

a. PD on rail surface across joint = 0.5mm.

Crane Rails a. PD on rail surface across joint = 0.5mm. = 0.5mm b. PD on

= 0.5mmCrane Rails a. PD on rail surface across joint = 0.5mm. b. PD on rail edge

b. PD on rail edge alignment across joint = 1mm.

= 1mm
= 1mm

4.8.4.11 Profile Steel Floor Decking

PD of dimension between deck edge trim and perimeter beam = ± 10mm for deck span in either direction.

Actual beam C L x ± Grid line Generic profile deck may span either direction
Actual beam
C
L
x ±
Grid
line
Generic profile
deck may span
either direction

= ± 10mm

4.8.5 Deviations Exceeding PDs

Inform the SO as soon as possible if checks show that the deviation in position of the steelwork as erected exceeds the PDs given above. Propose and carry out remedial measures as required.

NPQS C5-10 Structural Steelwork

5.

VERIFICATION AND SUBMISSIONS

5.1

Submission

5.1.1 Design Submission

When required in Clause 1.4.1, submit to the SO for acceptance calculations and drawings for the connection details within time as directed by the SO prior to commencement of the Works.

5.1.2 Shop Drawings

Submit to the SO for acceptance complete and coordinated shop drawings within time as directed by the SO prior to commencement of any works. Include all details of the steel structures incorporating at least the following information:

a. Number of pieces of steel sections

b. Dimensions

c. Tolerances

d. Connection details

e. Bearing locations and details

f. All other fabrication and erection details

5.1.3 Method Statement

Provide a detailed method statement to the SO for acceptance within directed time prior to commencement of any works. Include at least the following information:

a. A site plan showing the work layout area, position and type of cranes, access routes, datum level, setting-out lines, storage area, etc.

b. Fabrication procedure/manual, locations (local and/or overseas), list of subcontractors/suppliers and their scope of works, quality assurance system, etc.

c. Storage and handling.

d. Maximum size of structural steel components that can be delivered to the site.

e. Assembly of structural members on the ground level before erection, where partial or complete fabrication work is required on site.

f. Sequence and method of erection and assembly of structural members taking into account the site conditions, site constraints, site restriction and interface with other trades.

g. Detailed drawings and calculations for temporary works.

h. Details of proposed site inspection systems by the Accredited Inspection Body.

i. Details of staging, platforms and weather protection where site welding is to take place.

j. Remedial procedures for damaged steelwork during fabrication, transportation, storage, handling and erection.

k. Safety procedures for handling and erection of steelwork on site.

NPQS C5-10 Structural Steelwork

5.1.4 Construction Information

Provide the following information within time as directed by the SO prior to commencement of the Works:

a. Welder qualification records, welding procedure records, stud welding procedure records.

b. Details of welding procedures in accordance with ANSI/AWS D1.1 for all welds, including tack and sealing welds.

c. Details of proposed shop inspection system by the Independent Inspection and Testing Agency.

5.1.5 Programme

Provide a detailed programme to show the planned timing of the various items of work to be done within time as directed by the SO, including:

a. Preparation and submission of construction information

b. Order and delivery of materials

c. Fabrication

d. Application of protective coatings

e. Transportation to site

f. Erection

Include in the programme, the time required for all procedural trials, inspection and testing, and trial assemblies.

5.1.6 Material Certificates

Submit to the SO for acceptance, material certificates duly verified by the Independent Inspection and Testing Agency within time as directed by the SO prior to commencement of any work.

5.1.6.1 Mill Certificates

Provide mill certificates for every batch of supply confirming compliance with the specified standards before the supply of material to the works.

5.1.6.2 Test Certificates/Reports for Bolts and Inserts

Provide test certificates/reports and demonstrate by testing on 2% of actual materials used that bolts and inserts used in the Works conform to the specified requirements.

5.1.7 Inspection by ITA

Submit all reports from the Independent Inspection and Testing Agency to SO periodically as agreed with the SO.

5.1.8 As-built Drawings

Submit as-built drawings to the SO for record upon completion of the Works. Include information on all element type, sizes, position including deviation exceeding the permitted PD if any, connection and assembly details, and protective works applied if

any.

NPQS C5-10 Structural Steelwork

5.1.9 Quality Control Manual

Submit a Quality Manual containing a QA/QC programme for the Works to the SO for acceptance within directed time frame.

The Quality Manual is to include at least information on the following:

a. Quality policy

b. Organisation charts and responsibilities

c. Internal quality control and audits

d. Facilities and equipment

e. Calibration and testing of equipment

f. Testing and inspection procedures

Subcontractors and suppliers

5.2 Procedural Trial and Trial Assemblies

Carry out procedural trial and trial assemblies as agreed with the SO, including tests on material and workmanship in accordance with the Specification, prior to commencement of the Works. Give adequate period of notice as agreed with the SO.

Keep records of all tests and make them available to the SO and the Independent Inspection and Testing Agency for examination throughout the duration of the Works.

5.3 Inspection

5.3.1 Inspection of Accuracy of Fabrication and Erection

Provide inspection reports in agreed batches endorsed by the Independent Inspection and Testing Agency, verifying that the fabrication and erection of the works comply with the specified requirements.

5.3.2 Visual Inspection of Welds

Carry out visual inspection over the full lengths of all welds prior to any Non- Destructive Testing (NDT).

Immediately examine any welds that will be covered up before loss of access.

The acceptance criteria for visual inspection are to be in accordance with ANSI/AWS D1.1 Table 6.1.

5.4 Non-Destructive Testing of Welds

5.4.1 Scope of Inspection

Carry out Non-Destructive Testing as tabulated below unless otherwise agreed.

Inspection requirements may be reduced by agreement with the SO based on satisfactory performance in the initial tests.

Full Penetration Butt Welds Partial Penetration Butt Welds
Full Penetration Butt Welds Partial Penetration Butt Welds
Full Penetration Butt Welds Partial Penetration Butt Welds
Full Penetration Butt Welds Partial Penetration Butt Welds

Full Penetration Butt Welds

Full Penetration Butt Welds Partial Penetration Butt Welds

Partial Penetration Butt Welds

Full Penetration Butt Welds Partial Penetration Butt Welds
Full Penetration Butt Welds Partial Penetration Butt Welds

Version 1.0

Page 34

NPQS C5-10 Structural Steelwork

 

Examples:

Examples:

  Examples: Examples: MT / Thickness All thicknesses All thicknesses PT Frequency 50% (site welds
  Examples: Examples: MT / Thickness All thicknesses All thicknesses PT Frequency 50% (site welds

MT /

Thickness

All thicknesses

All thicknesses

PT

Frequency

50% (site welds 100%)

50% (site welds 100%)

UT /

Thickness

t max

3 mm

t max

3 mm

RT

   

Frequency

50% (site welds 100%)

50% (site welds 100%)

 

Fillet Welds

 

Examples:

 
 
 

MT / PT

Thickness

Fillet weld size 3 mm

 

Frequency

10% (site welds 100% but longitudinal welds 0.5m in each 10m or part thereof)

Thickness

Fillet weld size 20 mm

 

Frequency

20% (site welds 100% but longitudinal welds 1.0m in each 10m or part thereof)

UT / RT

As directed by SO

 

5.4.2 Hold Time Prior to NDT

For welds subject to NDT, carry out the testing at least 24 hours after the completion of the welds. For quenched and tempered steel, carry out NDT not less than 48 hours after the completion of the welds.

5.4.3 Magnetic Particle Testing (MT) and Penetrant Testing (PT)

Where magnetic particle testing (MT) is required in accordance with Clause 5.4.1(Scope of Inspection), the procedure and technique are to be in accordance with ASTM E709.

If Magnetic Particle testing is impractical, use Penetrant testing in accordance with the procedure and technique given in ASTM E165.

5.4.4 Ultrasonic Examination (UT)

Where ultrasonic testing is required in accordance with Clause 5.4.1(Scope of Inspection), the procedure and technique are to be made in accordance with ANSI/AWS D1.1 Section 6 Part F.

If ultrasonic testing is impractical, for example when the plate thickness is less than 8mm, use radiographic testing in accordance with the procedure and technique given in ANSI/AWS D1.1 Section 6 Part E.

testing in accordance with the procedure and technique given in ANSI/AWS D1.1 Section 6 Part E.

NPQS C5-10 Structural Steelwork

5.4.5 Radiographic Examination (RT)

Where radiographic testing is required in accordance with Clause 5.4.1(Scope of Inspection), the procedure and technique are to be in accordance with ASTM E94 and ASTM E747.

5.4.6 Acceptance Criteria and Corrective Actions

Acceptance criteria are to be in accordance with ANSI/AWS D1.1 Section 6 Part C. Propose corrective actions to the SO for acceptance if the welds do not conform to the acceptance criteria.

5.4.7 Weld Test Records

Record the results of all visual inspections and non-destructive testing and make all records available for inspection.