TS 2 STRUCTURAL STEELWORK FABRICATION AND ERECTION

CBH OPERATIONS PTY LTD 40 Miguel Road BIBRA LAKE WA 6163 Tel: (08) 9236 5350 Fax: (08) 9236 5370 www.cbh.com.au

TECHNICAL SPECIFICATION

TS 2 - STRUCTURAL STEELWORK FABRICATION AND ERECTION

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DOCUMENT CONTROL
CHANGE CONTROL POLICY
Any amendment to this standard must be recorded in the table below. If substantial changes are made a new version of the document shall be created to preserve an audit trail.

REV
A B C

DATE REVISED
15/07/2009 20/07/2009 30/04/2010

AUTHOR
T. Tyler T. Tyler T. Tyler

DESCRIPTION OF AMENDMENT
Reformatting, Previously TS 5 & 6 Rebranding

TS 2 OWNER

OPERATIONS AND ENGINEERING MANAGER

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TS 5 & 6 STRUCTURAL STEELWORK FABRICATION AND ERECTION

CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 SCOPE GOVERNING STANDARDS MATERIALS MARKING MATERIALS IDENTIFICATION SUBSTITUTION OF MATERIALS SPECIFIED COMPRESSION JOINTS FABRICATION SHOP ASSEMBLY PLATFORMS, WALKWAYS, STAIRWAYS & LADDERS TOLERANCES ENCASED STEELWORK INSPECTION PAINTING HANDLING, TRANSPORT & STORAGE HANDLING AND ERECTION GROUTING SITE MODIFICATION OF STEELWORK

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1.0

SCOPE
This specification establishes the principles to be followed in the design, fabrication and site erection of structural steelwork and the performance requirements of all operations necessary to complete this work. This specification is to be read in conjunction with the Scope of Works and General Provisions as outlined in Exhibit C.

2.0

GOVERNING STANDARDS
2.1 General Except where otherwise stated, the works shall be in accordance with the current issue, including amendments of the relevant Australian Standards. These should include, but not be limited to those identified herein. Except as modified by the requirements specified herein or the details on the drawings, work included in the specification shall conform to the applicable provisions of these publications.

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2.2

Standards AS 1101 AS 1111 AS 1112 AS 1163 AS 1237 AS 1252 Graphical Symbols for General Engineering ISO Metric Hexagon Commercial Bolts and Screws ISO Metric Hexagon Nuts, including thin Nuts, slotted Nuts and Washers Structural Steel Hollow Sections Flat metal washers for General Engineering purposes High Strength Steel Bolts with associated nuts and washers for Structural Engineering (ISO series) Coach Screws with ISO Hexagon Heads SAA Crane Code SAA Cold-Formed Steel Structures Code SAA Structural Steel Welding Code Welding of steel structures Part 2 Stud welding (steel studs to steel) Part 4 Welding of high strength quenched and tempered steels Part 5 Welding of steel structures subject to high levels of fatigue loading Welding stainless steels for structural purposes Hot dip galvanised steel bolts with associated nuts and washers for tower construction Hot-rolled steel flat products Structural steel hot-rolled plates, floor plates and slabs Structural steel Part 1 Hot-rolled bars and sections Part 2 Welded l sections Galvanised Coating of Ferrous Articles SAA Code for Fixing Platforms, Walkways, Stairs and Ladders Preferred Dimensions of Wrought Metal Products Plate SAA Loads on Bulk Solids Containers SAA Steel Structures Code Black Cup and Countersunk Bolts, Nuts and Washers. Glossary of Metal Welding Terms and Definitions

AS 1393 AS 1418 AS 1538 AS 1554 AS/NZS 1554.1 AS/NZS 1554.2 AS/NZS 1554.4 AS/NZS 1554.5 AS/NZS 1554.6 AS/NZS 1559 AS/NZS 1594 AS/NZS 3678 AS/NZS 3679 AS/NZS 3679 AS/NZS 3679 AS 1650 AS 1657 AS 2338 AS 3774 AS 4100 AS B108 AS Z5

Reference in this specification of specific clauses of the various codes is intended to highlight those points and shall not be taken to imply a lesser importance for all other applicable clauses or codes.

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2.3

Document Precedence If conflicting requirements occur in the documents, the order of precedence shall be: Australian Standards listed in the, Occupational health, Safety and welfare Regulations Schedule 1, with the amendments specified in this schedule. The Contract Documents, namely the Scope of Work and Drawings followed by the Specifications. Nominated and relevant Australian Standards. Local, Australian and International codes and standards.

If the Contractor finds any conflicting requirements in the contract the Contractor shall inform the Engineer before starting the work. Where a situation arises which is not covered by the documents, the Contractor shall adhere to internationally accepted design the engineering practices with regard to safety, material selection, constructability, operability and maintainability and as approved by the Engineer. 2.4 Documentation by Contractor The following documentation shall be forwarded to the Engineer: Quality Control Manual Inspection and test Plans Welding Procedures Material Certificates Non-destructive Examination Records Painting / galvanising Records Dimensional Inspection Records As-built Drawings / Sketches Release Certificates Bolt Torque Results if appropriate Shop Drawings

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3.0

MATERIAL CERTIFICATION
All material for fabrication including bolts, nuts and washers shall be clearly stamped / marked with the manufacturers numbers and cross-referenced to the certified material test report (CMTR) or certificate or compliance (COC). CMTRs from the manufacturer shall show the heat / batch number and mechanical and chemical properties derived from testing of the steel. Material received without certificates shall be quarantined, pending completion of the above. 3.1 Structural Steel Structural steelwork for use in buildings, open type structures, bins, or otherwise, shall be in accordance with Australian Standards. 3.2 Mill Test Certificate Copies of all Mill Test Certificates covering the chemical and physical properties of the steel used in the work shall be furnished to the Engineer on request and records shall be kept for inspection. 3.3 Units of Measurement The steelwork sections and holding down bolt diameters shall be metric units. 3.4 Material Supply All materials shall be of new and unused stock. All steel shall be free from rust, pitting and other defects. All material shall be thoroughly straightened in the shop without injury before being worked in any way. Material that has been split or permanently injured shall not be used. 3.5 Material Tests The Engineer reserves the right to have the Contractor submit for testing, as and when directed by the Engineer, test specimens of any material or item supplied under this Contract and used, or intended to be used in the structure. Any material or item failing to meet the requirements specified for the appropriate test or failing to comply in any way with the specification may be rejected entirely or, alternatively, the Engineer may direct that its use be confined to some particular part of the structure.

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In the event of the Engineer requiring a test specimen to be cut from a member already fabricated, and the test proving unsatisfactory, the member may be rejected altogether or repaired as directed by the Engineer at the Contractor's expense. Should the test prove satisfactory, all repairs to the member will be carried out at the Principal's expense. Should any test specimen fail to meet the required specification the entire cost of preparing the test specimen and carrying out the test shall be borne by the Contractor. All check analysis and mechanical tests shall be carried out in Australia in a laboratory approved by the Engineer and registered with the National Association of Testing Authorities, Australia.

4.0

MARKING OF FABRICATED STEEL

All marking of steelwork shall comply with the following requirements and shall be subject to the agreement of the Engineer. Each piece of steel work shall be distinctly marked by hand stamping and shall include orientation marks for ease of erection. Mark number shall not be placed on the bottom of baseplates or anywhere on the steelwork where they will be hidden after erection. The hard stamped mark shall be colour coded by placing a stripe of paint approximately 25 to 30 mm wide through the mark number. Another similar stripe shall be placed on the adjacent surface. The type of paint used shall be compatible with the final coat applied. Marking shall remain clear and legible for a minimum of 12 months when exposed to the weather. Small loose pieces shall be securely bagged or bundled and clearly marked for identification. Bolts, nuts and washers shall be in separated containers and each container shall be clearly marked for, size, type and quantity.

5.0

MATERIALS IDENTIFICATION
The full mark as given on the drawings shall be hardstamped in letters of 15 mm size.

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6.0

SUBSTITUTION OF MATERIALS SPECIFIED

Steel conforming to other than the nominated standards may be used, providing that the design requirements are shown to be satisfied and the Engineers agreement is obtained prior to the commencement of fabrication. Steel supplied in accordance with the nominated standards, but having sections and sizes greater in dimensions and relevant properties superior to those shown on the drawings, may be used if the Engineers agreement is obtained in each case. All material shall be new. No second-hand materials shall be incorporated in the works.

7.0

COMPRESSION JOINTS
Connection of members depending on contact bearing (i.e. columns to base plate) shall have their contact surfaces prepared for direct bearing stress.

8.0

FABRICATION
8.1 General All fabrication shall be carried out in a workmanlike manner generally in accordance with the applicable clauses in AS 4100. 8.2 Cutting and Bending Plates, members, brackets and other steel work shall be cut and bent in compliance with the following: Any plates thicker than 16 mm shall not be sheared unless otherwise approved by the Engineer. The ends of tubular and hollow sections shall be profiled to fit the shape of the members to which they connect, and shall not be sheared or flattened unless otherwise shown on the design drawings or agreed by the Engineer. Procedures for bending of materials shall be subject to approval by the Engineer. Normal strength steels up to grade 300MPa may under careful supervision be bent by limited heating to a temperature not higher than that required to produce a deep cheery red colour, and allowed to cool slowly. Higher strength steels shall not be heated without first obtaining the recommendations of the steel Manufacturer and the prior agreement of the Engineer.

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8.3

Punching and Drilling of Bolt Holes Punched holes shall not be made in material greater than 20 mm thick. Oversized and slotted holes for high strength bolts will not be permitted unless shown on the design drawings or otherwise agreed by the Engineer.

8.4

Machined Surfaces Where specified or shown on the design drawings, the contact bearing faces of adjoining members and plates shall be machined in accordance with Clause 14.4.4 of AS 4100. Rockers, rollers or hinge gearing sets shall be machined to the radii shown on the design drawings, with the axis of rotation at right angles to the direction of the motion of the structural members which they support. Machining tolerances shall be as shown on the design drawings.

8.5

Camber Trusses, beams and plate girders having spans greater than 12 m shall be fabricated with cambers of five (5 mm) millimetres under the self-weight, unless noted otherwise on the design drawings.

8.6

Splicing in Members All structural members shall be single lengths, except where splices are shown on the design drawings, or where the Engineer has given prior written approval. For additional splices, the Contractor must demonstrate the need and provide calculations for the review of the Engineer prior to fabrication. Splices must be designed to develop the full splices member strength. Where shown on the design drawings, column ends with full bearing splices shall be machined in accordance with Clause 14.4.4.2 of AS 4100.

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8.7

Boxed Members Abutting edges shall be connected and sealed with a continuous weld. Weld reinforcement ground flush only where shown on the drawings. Stiffeners and other details that will be enclosed within the box member shall be subject to inspection by the Engineer before the closure plates are welded into place. Where steelwork is required to be galvanized, holes shall be provided in boxed members to prevent distortion and explosions during the galvanizing process.

8.8

Connections In general, shop connections shall be welded and field connections shall be bolted, unless otherwise shown on the drawings. All bolting and welding shall conform to AS 4100 Steel structures and the specification. Bolted Connections All bolts, nuts and washers shall be galvanised. Structural connections shall have a minimum of two (2) bolts. Bolting procedure shall be 8.8/TB unless noted otherwise on the drawings. All high strength bolts shall be installed in accordance with AS 4100. The Contractor shall supply bolts, nuts and washers of each type, size and length for both shop and field connections are required for erection and extra amounts of field bolts, nuts and washers as follows; a) 5% extra for each bolt type for the first 1000 required. 3% extra for each bolt type for the remainder required in excess of 1000. b) Structural bolts that have been fully tensioned (8.8/TB and 8.8/TF) shall be replaced if they are undone and would need to be retightened.

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8.9

Shop Errors Fabrication errors or potential errors resulting from incorrectly detailed components are to be reported immediately to the Engineer. The Engineer will consider the action required for correction or modification of the work. Should corrections be necessary, written instructions will be given to the Contractors to carry out such work to the account of the responsible party. Should fabrication errors be found during erection, the Contractor will be advised and repairs and/or modifications as considered necessary by the Engineer will be the account of the Contractor.

8.10

Inspection During Fabrication During fabrication the Contractor shall permit the Engineer or the nominated representative free access to the Fabricators Works at all reasonable times for the purpose of carrying out inspections. Units shall be laid out and fabricated as necessary so that all parts are accessible for final inspection before transportation to the site. Where steel has been inspected by the Engineer at the shop, before being delivered to the site, such inspection shall not relieve the Contractor of the responsibility for the correctness of the fabricated steel.

8.11

Material All material shall meet the requirements of AS4100 Structural Steel Clause 2.2. Steel bolts, nuts and washers shall be to the requirements of Clause 2.3, and the steel castings to the requirements of Clause 2.4. Crain rail steel shall be to the requirements of AS1085 and BHP Standards.

8.12

Surface Preparation of Steel and Components All surfaces to be welded shall be clean and free from paint, oil, debris, scale, oxides and other foreign material detrimental to welding, for a distance of at least 25 mm from joint preparation.

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8.13

Welding All welding shall conform to the requirements of AS/NZS1554 as appropriate. Welding of steel studs to structural steel shall be detailed in AS/NZS1554.2. All welding shall be general purpose (GP) unless noted otherwise on the drawings. Where welding is required that does not conform to the above codes, the necessary procedures and instructions shall be indicated on the Engineers drawings. All welds shall be made with the appropriate grade of electrode suitable for the type of steel being welded. Welds shall be thoroughly chipped to remove slag and shall be the full size specified and/or as shown on approved drawings. Unless otherwise shown, all fillet welds shall be continuous welds. Intermittent welds will not be permitted where members are exposed to weather or corrosive atmosphere unless the spaces between are continuously seal welded. Unless otherwise shown, all butt welds shall be complete penetration butt welds and where possible, shall be double V butt welds except that in the case of butt welds in plate 40 mm and more in thickness shall be made with low hydrogen electrodes. Over reinforcement of butt welds and pronounced bumps shall be ground off. Subject to the Engineers approval. Beams, flange plates, web plates and cord members of long trusses may be butt welded in the shop to form any long lengths required provided that such splices do not come within the middle third of the member, in the case of compound members, the splices in the individual units shall be staggered by not less than 600 mm. all butt welds in tubular and boxed members shall be backed by suitable mild steel backing rings or plates. To enable complete assemblies to be erected, site welding of individual members attached to main shop fabricated pieces shall be permitted as indicated on the Engineers and fabrication drawings. The individual members shall be welded to their main components at ground level. Adequate mobile welding facilities shall be provided for this operation. When the occasion arises due to discrepancy, inaccuracy or other reasons, site welding may be used. All relevant details and procedures must be approved by the Engineer before site welding can commence.

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Fabrication drawings of welded connections shall specify as a minimum: a) b) c) d) e) f) Relevant design standards Specification grade of parent weld/electrode material Location, type, size of weld and effective lengths Weld category GP or SP Details of non-standard welds NDT (non destructive testing) requirements

Qualification of welding procedures and personnel shall be carried out as detailed in AS/NZS 1554. Weld procedures shall be approved and personnel shall be qualified prior to commencing welding on structural steel or components. Documentary evidence of personnel qualifications shall be submitted to the Engineer for review prior to fabrication.

9.0

SHOP ASSEMBLY
Sections of the fabricated steelwork shall be shop assembled when specified on the drawings. During shop assembly, drifting of misaligned holes shall not be permitted. Misaligned holes shall be drilled and reamed to a larger size and larger bolts fitted, subject to the agreement of the Engineer.

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10.0

PLATFORMS, WALKWAYS, STAIRWAYS AND LADDERS

The platforms, stairways and ladders and associated attachments shall conform to: 10.1 AS 1657 Fixed platforms, walkways and ladders design, construction and installation and the following requirements.

General All decking shall be firmly fixed to the supporting steelwork. Shop fixings shall be welded and field connections shall be bolted unless otherwise shown on the drawings. Bolts or other fixings on the surfaces of platforms, landings and walkways shall be countersunk flush with the surfaces.

10.2

Guard Rails The dimensions of components used for guard railing shall be as shown on the drawings or on the recommendations of AS 1657 when not shown on the drawings. The top rail of all railing shall present no obstruction that may break or prevent a handhold. All welds shall be continuous and ground smooth.

10.3

Floor Grating Floor gratings shall be as specified on the approved drawings. Gratings shall be furnished to be continuous over two spans, or more where practicable. Grating panels shall be banded. Longitudinal and cross bars in adjacent sections shall be in line when erected end to end. Where removable grating is required, the maximum grating panel shall be normally 1500 mm x 1200 mm wide.

10.4

Raised Angular Pattern Floor Plates Floorplates shall be skid resistant BHP raised pattern (or equal) Grade 250 steel plates to AS 3678, not less than 6 mm thick welded or bolted to the supporting steel as noted on the design drawings. Floorplate shall be fabricated with lengths to be continuous over two spans or more with practical, smooth cut to the dimensions indicated on the design drawings.

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When removable froorplate is required, holes in the supporting steel shall be drilled in the field after erection, using the shop drilled, countersunk holes in the floorplate as a template to ensure a proper fit. A minimum of four (4) bolts per piece shall be provided. Two (2) lifting holes shall also be provided in each removable floorplate.

11.0

TOLERANCES
Tolerances for shop fabricated steel and field erected steel shall comply with the relevant requirements of AS 4100, unless specified otherwise on the design drawings or as specified below. The deviation in plan position of a column shall not exceed 5 mm from its specified position at any point. The base of a column shall be within 5 mm of its correct level and the top of the column shall be within 3 mm of its correct level. The deviation in level of a beam or a girder shall not exceed 5 mm from its specified level. Tolerances for overhead crane rails shall comply with the relevant requirements of AS 1418.1, Section 7 in addition to the following: The centre to the centre distance between the two crane rails shall not deviate from the spacing specified on the drawings by more than 3 mm. The plan position of each crane rail shall not deviate by more than 3 mm from the specified position shown on the drawings. The level of the top of the rail in an unloaded condition shall not deviate from the elevation shown on the drawing s by more than 3 mm. The horizontal alignment of each rail end at joints shall not deviate by more than 2 mm. the top face of each rail end at joints shall be flush.

12.0

ENCASED STEELWORK
Steelwork shall be encased in concrete as detailed on the approval drawings and shall comply with the following requirements: Steelwork shall not be encased or built in until all connections and surface preparations have been reviewed and approved by the Engineer. Welding of reinforcing steel / anchors shall be carried out as detailed in AS/NZS 1554, Part 3, Welding of Reinforcing Steel. Concrete shall be Grade 32 MPa with a maximum aggregate size of 10 mm, unless specified otherwise on the drawing.

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13.0

INSPECTION
Welding of shop fabricated structural steel and field welding shall be subjected to Non Destructive Tests (NDT) as follows: Visual inspection of 100% of all welds shall be performed. Fillet welds, 5% by Magnetic Particle Inspection (MPI). Full and partial penetration butt welds, 10% by radiography. Levels of inspection shall be increased in the event that the defects exceed the level as given in Tables 6.2.1 and 6.2.2 of AS/NZS 1554.1.

14.0

PAINTING AND PROTECTIVE COATINGS

Corrosion protection of steel and components shall be carried out as described in Standard Specification TS 4 - Painting and Protective Coatings or as nominated on the drawings. During site handling, storage and erection the Contractor shall take all necessary precautions to prevent damage to the protected steelwork surfaces. All painted and protective coating to the steelwork damaged by the Contractor during erection shall be cleared, prepared and restored in accordance with the standard specification above. The Engineer reserves the right to inspect all fabricated structural steel (shop and field) prior to application of protective coatings The Contractor shall give the Engineer three (3) working days written notice of intension to proceed with the application of the coatings to any steelwork.

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15.0

HANDLING, TRANSPORTING AND STORAGE

Handling of structural steelwork by the Contractor during all phases of fabrication and erection shall comply with the following requirements: Steelwork shall be handled and stored by methods and equipment that will not result in overstress, deformation or damage to protective coatings. Members shall not be stored directly in contact with the ground. Members bent or buckled by the Contractor during handling shall be liable to rejection. Any steelwork that is deformed as a result of handling, storing and transporting and which prevents the proper assembling and fitting up of parts shall be replaced or corrected by the Contractor. The method of correction shall be subject to the agreement of the Engineer. Damage to paintwork during handling and erection shall be repaired in accordance with Standard Specification TS 4. Bolts, nuts and washers shall be stored in grit free containers, in weatherproof premises. Loose pieces for connections shall be attached to their respective members and clearly marked for identification. During site handling, storage and erection, the Contractor shall take all necessary precautions to prevent damage to painted or other protected steelwork surfaces. All protected steelwork damaged by the Contractor during handling and erection shall be cleaned, prepared and restored in accordance with Standard Specification TS 2.

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16.0

HANDLING AND ERECTION OF STRUCTURAL STEEL

Handling and erection of steelwork shall comply with Section 15 of AS 4100 and the following requirements. The Contractor shall submit to the Engineer for agreement, details of the equipment and methods proposed for use in the erection of the steelwork. All erection gear and equipment shall be of adequate strength and comply with all applicable Statutory Acts and Regulations. The agreement of the Engineer shall not relieve the Contractor of responsibility for the adequacy and safety of the work during erection. During erection, the work shall at all times be securely bolted, guyed or braced. The Contractor shall ensure the stability of the structure at all stages or erection and shall supply the necessary temporary bracing. At the request of the Engineer the Contractor shall submit certified engineering computations for stability of the structure. Prior to erection of steelwork, concrete surfaces shall be prepared and levelling plates or shims set in place. All shims and plates shall be galvanised. All erection bolts used in welded construction may be tightened securely and left in place or removed and the holes filled with weld metal and ground flush. Permanent welding shall not be undertaken until correct alignment, plumbing and levelling has been completed and approved by the Engineer. Drift punching to match misaligned holes will not be permitted. Misaligned holes shall be drilled and reamed to a larger size and large bolts fitted or corrected by other means to the agreement of the Engineer.

All bolting carried out by the Contractor shall comply with the following requirements: a. Bolts shall be assembled with washers under the part to be turned and shall conform to the requirements of AS 4100. b. High strength bolts shall be tightened in accordance with AS 4100. c. Load indicating and other types of bolts designed for special tightening procedures shall only be installed where shown on the drawings or with the agreement of the Engineer.

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17.0

GROUTING
17.1 General Grouting for base plates shall be of two (2) types, flowable non-shrink and dry pack mortar and shall be indicated on the design drawing. 17.2 Flowable Non-Shrink Grout Epirez 5137 Epoxy grout or equivalent approved flowable non-shrink grout shall be mixed and placed in accordance with the manufacturers instructions in the locations shown on the drawings. 17.3 Non-Shrink Grout (Structural) The acceptable grout shall be an approved proprietary brand. Grout shall as dry as practicable for the purpose. The grout shall be rammed under the full area of the baseplate, either by ramming from the opposite sides simultaneously or ramming against a fixed form. The edges of the grout shall be neatly tapered at 45 from the baseplate edge to the concrete foundation.

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SITE MODIFICATION OF STRUCTURAL STEELWORK

17.1 General No modification that is liable to effect the strength of a structural member, the efficiency of a joint, or the integrity of a structure shall be made without the prior approval of the Engineer. Such field fabrication and sub-assembly as may be necessary shall conform with the requirements of the specifications. 17.2 Modifications and Corrections Procedures and method shall be submitted to and approved by the Engineer. 17.2.1 Cutting Site cutting shall be wherever possible by a mechanical process. Where flame cutting is necessary, an allowance shall be left for grinding of ragged edges to ensure a smooth finish. 17.2.2 Holding Holes for bolts shall be drilled. Burning of such holes will not be permitted. Correction of misaligned holes may be achieved by reaming or, subject to the approval of the Engineer, by filling badly misaligned holes with weld metal, grinding flush and redrilling correctly. 17.2.3 Repositioning Where welded fitments need positioning, the existing weld shall be removed, where possible, by chipping, grinding or gouging. Where the fitment has been removed, the affected area shall be ground smooth. Fitments shall be removed using the same attachment as specified on the approved detail drawings. 17.2.4 Finishing Wherever remedial work has been carried out, the affected area shall be cleaned, burrs, slag and weld spatter removed and the paintwork made good in accordance with Standard Specification TS 4.

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