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Code: 3217.46.BASG.36908

PROJECT/UNIT
NEW PORT-HARCOURT BASE POWER
GENERATION PROJECT

Page 1 of 25

Rev
0

GENERAL SPECIFICATION FOR


STRUCTURAL STEELWORK

MATERIALS AND FABRICATION


AT

NAOC PORT-HARCOURT BASE, NIGERIA

H.
D. AKANO
R. OMIETIMI
DORDOR
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21/06/12

Date

Rev

Issued for Review


Description of
Revision

Prepared

Checked

Approved

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Code: 3217.46.BASG.36908
Rev

Page 2 of 25

CONTENTS
1.

SCOPE

2.

CODES AND STANDARDS


2.1
2.2
2.3
2.4

BRITISH CODES AND STANDARDS


PROJECT SPECIFICATIONS
STANDARD STEELWORK DETAILS
AMERICAN STANDARDS

3.

TYPES OF CONSTRUCTION

4.

STEEL STRUCTURES
4.1
4.2
4.3
4.4

5.

MATERIALS
STRESSES
CONNECTIONS
TEMPORARY RESTRAINTS

FABRICATION
5.1
5.2
5.3
5.4
5.5
5.6

ERECTION ARRANGEMENT DRAWINGS (MARKING PLANS)


FABRICATION DRAWINGS
INSPECTION
PROPRIETARY ITEMS
TRACEABILITY OF MATERIALS
MARKING STEELWORK

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5.7
5.8
5.9
5.10
5.11

6.

Code: 3217.46.BASG.36908
Rev

Page 3 of 25

MACHINING
DRESSING
ALIGNMENT OF HOLES
ASSEMBLY
SAFETY-HOLES FOR MANLOCK BOLTS

WELDING
6.1
6.2
6.3
6.4

WELDING PROCEDURES
WELDER QUALIFICATION
NON-DESTRUCTIVE TESTING OF WELDS
SCOPE AND FREQUENCY OF INPECTION

7.

FLOORING

8.

STAIRWAYS

9.

LADDERS

10.

HANDRAILS AND TOE PLATES

11.

PAINTING

12

ERECTION MARKING

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13.

COLOUR CODING

14.

FIREPROOFING

15.

SHIPPING

Code: 3217.46.BASG.36908
Rev

Page 4 of 25

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1.

Code: 3217.46.BASG.36908
Rev

Page 5 of 25

SCOPE
This Specification defines the basic requirements for detailing, supply
and fabrication including NDT, coating, packaging and shipping of
steelwork for structures, buildings and platforms for NEW PORTHARCOURT BASE POWER GENERATION PROJECT, NIGERIA.

2.

CODES AND STANDARDS


All work shall conform to the latest requirements of European Codes or
British Standards and any local related statutory regulations, as listed
in this Specification. In case of conflict between the various Codes and
Standards, and/or this Specification, reference shall be made back to
Employer or approved agent for resolution.
Unless specified otherwise, the international system of metric units
(S.I.) is to be used.
Structural steelwork shall be designed in accordance with BS 5950
Part 1, and information supplied on drawings.

2.1

British Codes and Standards


BS EN 287 Approval Testing of Welders for Fusion Welding
Pt. 1: 1992 Steels
BS EN 288 Specification and Approval of Welding Procedures for
Metallic Materials

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Pt. 1: 1992
Pt. 3: 1992

Code: 3217.46.BASG.36908
Rev

Page 6 of 25

General Rules for Fusion Welding


Welding Procedure Tests for Arc Welding of Steel

BS EN 571 Pt. 1: 1997

Non-Destructive Testing - Penetrant Testing .


General Principles

BS EN 970

Non-Destructive Examination of Fusion


Welds Visual Examination
Non-Destructive Examination of Welded
Joints - Ultrasonic Examination of Welded
Joints

1997

BS EN 1714 1998

BS EN 10025 1993

Hot Rolled Products of Non-Alloy Structural


Steels. Technical Delivery Conditions

BS EN 10113

Hot Rolled Products in Weldable Fine Grained


Structural Steels
Pt. 2: 1993 Delivery Conditions for
Normalised/ Normalised Rolled Steels.

BS EN 22553 1995

Welded, Brazed and Soldered Joints - Symbolic


Representation on Drawings

BS 4

Structural Steel Sections. Specification for Hot


Rolled Sections

BS 11

Pt. 1: 1993

1985

Specification for Railway Rails

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Code: 3217.46.BASG.36908
Rev

Page 7 of 25

BS 729

1971

Specification for Hot-Dip Galvanised Coatings


on Iron and Steel Articles

BS 3692

1967

Specification for ISO Metric Precision Hexagon


Bolts, Screws and Nuts

BS 4190

1967

Specification for ISO Metric Black Hexagon


Bolts, Screws and Nuts

BS 4320

1968

Specification for Metal Washers for General


Engineering Purposes

BS 4592

Pt.1: 1995

Industrial Type Metal Flooring, Walkways and


Stair Treads, Specification for Open Bar Gratings

BS 4848
.

Pt 4: 1972

Hot-Rolled Structural Steel Sections Equal and


Unequal Angles

BS 4872

Specification for Approval Testing of Welders when Welding .


Procedure Approval is not required

BS 4921

1988

BS 5135

1984

BS 5395

Pt. 3: 1985

Specification for Sheradised Coating on Iron or


Steel
Specification for the Process of Arc Welding of
Carbon and Carbon Manganese Steels
Stairs, ladders, and walkways. Code of Practice
for the design of industrial type stairs,
permanent Ladders and walkways.

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BS 5950

Structural
Pt. 1: 1990

Pt. 2: 1992

2.2

Code: 3217.46.BASG.36908
Rev

Page 8 of 25

Use of Steel in Building

Code of Practice for Design in Simple and


Continuous Construction - Hot Rolled Sections
Specification for Materials, Fabrication .
, and Erection - Hot Rolled Sections

Pt. 5: 1998

Code of Practice for Design of Cold ,


Formed Sections

BS 6072

1981

Method for Magnetic Particle Flaw Detection

BS 6323

1982

Seamless and Welded Steel Tubes for


Automobile, Mechanical and General
Engineering Purposes

BS 7191

1989

Weld able Structural Steels for Fixed Offshore


structures

Project Specifications

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10-CA-E-27012
Erection
2.3

Code: 3217.46.BASG.36908
Rev

Page 9 of 25

Specification for Structural Steelwork

Standard Steelwork Details


Welding Symbols
TO BE IN ACCORDANCE Typical Connections
WITH AGIP/NAOC PLANT Flooring Penetrations
STANDARD PRACTICE
Handrails
Stairs
Ladders
Stiles and Low Walkways
Fireproofing

2.4

American Standards
ASME SEC IX PT QW ART III Welding Performance Qualifications
(Boiler and Pressure Vessel
Codes)

3.

TYPES OF CONSTRUCTION
This Specification applies to the use in structures of hot rolled steel sections,
plates and tubular shapes. Cold formed sections may be used for purlins and
cladding rails in non-aggressive and heated environments.

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Code: 3217.46.BASG.36908
Rev

Page 10 of 25

The selected design shall take account of safety and ease of erection,
accessibility for painting and general maintenance. Lattice type structures,
other than roof trusses, should therefore be minimised.

4.

Where indicated, steel structures shall be fireproofed in accordance with


AGIP/NAOC Plant standard practice.
Workshop fabrication of structural steelwork by welding is preferred. Field
connections shall be bolted, except as noted on the design drawings.
Connection details shall make provision for safe erection, e.g. by use of
seating cleats, etc.
STEEL STRUCTURES

4.1

Materials

All material shall be from new stock.

Structural steel materials shall be in accordance with Appendix A of


this specification.

All bolts shall be grade 8.8, in accordance with Appendix A of this


specification.

Rolled sections shall conform to BS 4.

Steel tubes shall conform to BS 6323.

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Code: 3217.46.BASG.36908
Rev

Page 11 of 25

All nuts and bolts shall be supplied sherardised, but may be supplied
galvanised providing the coating allows full free running of the nuts
and washers without the threads having to be reworked or cut.

When the design drawings do not specify the grade of steel intended
for connections and fittings, the appropriate grades are as specified in
Appendix A.
Stresses

4.2

4.3

Design stresses shall be in accordance with BS 5950 : Part 1.

For structural elements continuously exposed to heat above 260C


design stresses shall be reduced in proportion to the reduction in yield
strength at the design temperature.

Connections

High tensile bolts shall be used for all site connections. Minimum size
of bolts for main connections shall be 20mm diameter. Main
connections shall include main beam to beam, main beam to column,
column splices, main bracing, crane brackets and all beams carrying
equipment loads, except as noted on design drawings.

M12 or M16 bolts may be used for site connections of secondary beams
(up to 250mm deep), purlins, light bracing, platforms, framing, and
similar members, except as noted on the design drawings.

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4.4

Code: 3217.46.BASG.36908
Rev

Page 12 of 25

Welding or bolting shall be used for shop connections. Except where


butt welds are called for, all welds shall be continuous fillets, unless
otherwise noted on the drawings.

All main connections shall be provided with a minimum of two M20


bolts.

Lock nuts shall be provided for all connections securing runway beams
to main framing, members supporting vibrating equipment, and/or
where stress reversal occurs.

Temporary Restraints
The design drawings shall show the positions on the structure where
temporary bracing or restraints are necessary until walls, floors or other nonsteel structures are built.

5.

FABRICATION

Fabrication shall comply with the requirements of BS 5950: Part 2.

The radius of re-entrant flame cuts shall be as large as possible, but


not less than 20mm, except in small members where this is
impracticable.

Ends of columns shall be sawn square. Column end plates shall be


measured for flatness with a straight edge not exceeding 1m long. The
end plate shall be machined if the gap between the plate and straight

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5.1

5.2

Code: 3217.46.BASG.36908
Rev

Page 13 of 25

edge exceeds 0.75mm. Joint assembly of column and end plate shall be
jigged.
All fabricated frames shall be suitably braced to prevent distortion
during transit.

Frames, platforms, stairs and handrails shall be shop assembled in the


largest units suitable for handling and transportation.

Attachments to pressure vessels are not covered by this Specification.

Erection Arrangement Drawings (Marking Plans)

Marking plans shall be prepared by the Steelwork Fabricator showing


plans and elevations at a scale large enough for erection marks for all
members to be shown.

The erection arrangement drawings shall show grid locations as


indicated on the design drawings, main dimensions, member levels and
centre lines. Enlarged scale details shall be shown where required to
show the assembly of members.

Fabrication Drawings
Fabrication drawings (based on standard drawings where applicable) shall
show all necessary details and dimensions to enable fabrication of
components to proceed.

5.3

Inspection

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Code: 3217.46.BASG.36908
Rev

Page 14 of 25

The Steelwork Fabricator shall record all testing of materials, weld


equipment, consumables, dimensional checks, surface checks, weld
inspections, protective treatment, etc.
5.4

Proprietary Items
All proprietary items shall be used in accordance with the Manufacturer's
recommendations and instructions.

5.5

Trace ability of Material


All steel and bolts supplied ex-mills or from merchant's stock shall be covered
by test certificates (including impact tests) and each fabricated component
shall be traceable to a certificate.

5.6

Marking Steelwork

Individual pieces shall be capable of positive identification at all stages of


fabrication.

Completed components shall be marked with a durable and distinguishing


erection mark in such a way as not to damage the material. Hard
stamping may be used, except where otherwise specified on the design
drawings. Hard stamping shall not be within 100mm of any weld.

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Where areas of steelwork are indicated on the drawings as being


unmarked, they shall be left free of all markings and hard stamping.

5.7

Code: 3217.46.BASG.36908

Machining
The thickness shown on the drawings of elements that require machining
shall mean the minimum thickness after the machining operations.

5.8

Dressing

Cut edges shall be dressed to remove burrs and irregularities. Holes shall
be dressed as required to remove burrs and protruding edges.

Sharp edges shall be dressed, but a 90 rolled, cut, or sheared edge is


acceptable without further treatment.

5.9 Alignment of Holes


All matching holes for fasteners or pins shall align with each other so that
fasteners can be inserted without undue force through the assembled members
in a direction at right angles to the faces in contact. Drifts may be used but
holes shall not be distorted, nor cause distortion to the final assembly.
5.10

Assembly

All components shall be assembled within the tolerances specified in


BS 5950, and in a manner such that they are not bent, twisted or
otherwise damaged.

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Code: 3217.46.BASG.36908
Rev

Page 16 of 25

Drifting of holes to align the components shall be permitted, but must


not cause damage or distortion to the final assembly.
Components shall be checked for dimensional accuracy and conformity
to drawings.
Fabricated components which are stored prior to being transported shall
be stacked clear of the ground and arranged so that water cannot
accumulate. They shall be kept clean and supported in such a manner
as to avoid permanent distortion.
Individual components shall be stacked and marked in such a way as to
ensure that they can easily be identified.

5.11 Safety-Holes for Manlock Bolts


In order to enable steel erectors to clip their safety harnesses to steelwork
with Manlock bolts, 22mm diameter holes shall be provided adjacent to all
connections. As a general guide line and to give the Erectors maximum
working scope, holes should be positioned as follows:

Beam to Column Connection


Three separate holes required:
a) 500mm above top flange of beam, on centre line of column
web.
b) 500mm below bottom flange of beam (or haunch) on centre
line of column web.
c) 500mm from end of beam, on centre line of beam web.

Beam to Beam Connection

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Code: 3217.46.BASG.36908
Rev

Page 17 of 25

Two separate holes required:


a) 500mm from centre line of connection beam, through the
web of the fixed beam.
b) 500mm from end of beam to be fixed, through centre line of
beam web.
This list may not cover every circumstance. It is the responsibility of the
Fabricator to position the holes, e.g. the 500mm dimension may be varied to
suit a particular requirement. Holes must be provided (and allowed for in
any calculation) at every connection. Where it is impractical to drill a hole
through a member, welded on lugs, cleats, or shaped plates with the requisite
hole shall be provided.
6.

WELDING

Welding shall be in accordance with BS 5135.

Welding symbols shall be in accordance with BS EN 22553.

All welding shall be performed in an area protected from rain, wind


and air-borne dust and sand.

Part to be welded shall be carefully prepared. Alignment, jigging and


welding sequences shall be such as to minimise distortion and residual
stress.

Butt welds shall be made in at least two passes such that filler metal is
deposited over the whole thickness of the joint.

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6.1

6.2

Code: 3217.46.BASG.36908
Rev

Page 18 of 25

Prepared weld profiles shall be checked by gauges before welding.

Welding Procedures

Written welding procedures shall be prepared and tested in accordance


with BS EN 288: Part 3.

All weld procedures shall be qualified to suit the design temperature


specified in Appendix A, and due consideration shall be given to the
requirements of Appendix D of BS 5135 as appropriate. All samples
shall be impact tested with a minimum acceptance criteria of 27J min
average (average of three specimens), 20J min (individual value).

The procedure shall identify material, weld geometry, tolerances,


welding process, pre-heat temperature and welding position to be used.

Welding procedures shall be qualified by procedure qualification and


shall be approved by an independent Inspection Authority.

Welding Procedure sheets shall be made available to the welder prior to


the commencement of the work and shall be available to the Design
Engineer or Inspection Authority on request.

Welder Qualification

Welders shall be tested to meet the requirements of BS EN 287: Part 1,


and/or ASME Section IX.

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6.3

Code: 3217.46.BASG.36908
Rev

Page 19 of 25

In the case of welders engaged on fillet welding only, BS 4872: Part 1.

Welder testing shall be witnessed and certificates endorsed by an


independent Inspection Authority.

Certificates may be updated at six-monthly intervals, subject to the


welder having been engaged on appropriate work in the intervening
period.

Non-destructive Testing of Welds

Visual inspection shall be made in accordance with guidance given in BS


EN 970, after completion of all welding over the full length of the weld.

All NDTs shall be performed by personnel qualified to a recognised


national or international standard (e.g. PCN, etc.).

Magnetic particle inspection (MPI) shall be in accordance with the


recommendations given in BS 6072.

Dye Penetrant Inspection (DPI) shall be used in accordance with the


recommendations given in BS EN 571-1.

The test results shall be recorded and be available for inspection by the
Design Engineer.

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6.4

Code: 3217.46.BASG.36908
Rev

Page 20 of 25

Where ultrasonic examination is required, it shall be made in


accordance with BS EN 1714, level C.

Scope and Frequency of Inspection


All welds shall be visually inspected along 100% of their length. In addition
NDTs shall be performed on the following:
a) Fillet welds with throat thickness greater than 15mm shall be MPI tested.
b) Fillet welds where the connecting material is thicker than 20mm shall be
MPI tested.
c) Butt-welds where the connecting material is 15mm or thinner shall be
MPI tested.
d) Butt-welds where the connecting material is thicker than 15mm shall be
ultrasonically tested.
Non-destructive testing shall be carried out for the first ten identified joints of
each type, having the same basic dimensions, material grade and weld
geometry, welded to the same procedures. Thereafter one in five joints of
each butt-welded type, and one in ten joints of each fillet-welded type, shall
be tested.
The acceptance criteria for any welding shall be in accordance with BS 5135
Category B.
Where field welding is used, 100% of all types of weld shall be subjected to
NDT. All field welds shall be MPI/DPI tested as a minimum.

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7.

Code: 3217.46.BASG.36908
Rev

Page 21 of 25

FLOORING

Standard Details shall be in accordance with AGIP/NAOC Plant Standard


Practice.

Open grid flooring shall be serrated rectangular open grid type with load
bearing bars 30mm deep x 5mm thick at 30mm cross centres with cross
bars at 100mm centres, hot dip galvanised after fabrication, and
complying with BS 4592: Part 1 (see also Appendix A to this Specification).

Open grid flooring shall be attached to the supporting steelwork with clips
or other effective means. Holes or cut-outs in panels shall be made by the
flooring manufacturer and have perimeter stiffening strips or toe plates
welded in. This work shall be carried out before galvanising.

Solid floor plate shall have a raised pattern affording a non-slip surface
and shall be 6mm minimum thickness exclusive of pattern.

Solid floor plates shall be attached to the supporting steelwork with


proprietary connectors, unless otherwise noted on the design drawings.
Unsupported edges shall have a 60 x 10mm butt-strap. A 13mm diameter
drainage hole shall be provided for every 1.5m of floor plate, with a
minimum of one hole per panel, unless shown otherwise on design
drawings.

Deflections for any floor panel shall not exceed span/200 or 10mm
whichever is smaller.

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8.

9.

Code: 3217.46.BASG.36908
Rev

Page 22 of 25

Galvanising shall be in accordance with BS 729.

STAIRWAYS

Standard Details shall be in accordance with AGIP/NAOC Standard


Practice.

Stairs shall have a minimum clear width between stringers of 750mm.


Main access and escape stairs shall have a minimum clear width of
1000mm, unless otherwise required by local regulations.

Treads shall be serrated rectangular pattern open grid type (25mm x


5mm bearing bars at 30mm cross centres with bars at 100mm cross
centres) with non-skid abrasive nosings, hot-dip galvanised after
manufacture for 750mm width stairs. For 1000mm wide stairs, 30mm x
5mm bearing bars at 30mm cross centres shall be used.

LADDERS
Standard Details shall be in accordance with AGIP/NAOC Standard Practice.

10

HANDRAILS AND TOE PLATES


Standard Details shall be in accordance with AGIP/NAOC Standard Practice

11.

PAINTING

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Steelwork shall be prepared, primed and shop painted in accordance with


AGIP/NOAC Standard Practice.

Steelwork to be galvanised shall be in accordance with BS 729.

Steelwork to be fireproofed shall be prepared and primed in accordance


with AGIP/NAOC Standard Practice.

In order to minimise coating damage all reasonable care shall be taken


when handling steelwork between stages in painting, and especially when
slinging and loading steelwork which has received its final coat.

No material shall be shipped until the final shop coat of paint is


thoroughly dry and clearly colour coded.

Adequate packing, crating, blocking and/or bracing shall be provided to


prevent damage to the fabricated material while loading, in transit and
while unloading.
Paint shall be excluded from areas within 50mm of joints to be field
welded.

12.

Code: 3217.46.BASG.36908

Temporary steelwork shall be painted white or fluorescent.

ERECTION MARKING

Every component which is individually assembled or erected at the site


shall be allocated an erection mark.

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13.

Code: 3217.46.BASG.36908
Rev

Page 24 of 25

Members which are identical in all respects may have the same erection
mark.
Erection markings corresponding to erection drawings shall be painted in
letters a minimum of 40mm high on all members.
All bundles shall be tagged with non-destructible labels.

COLOUR CODING
All fabricated structural steel, including galvanised steel, shall be identified
with an approved colour code.

14.

FIREPROOFING
Fireproofing materials shall be applied in accordance with AGIP/NAOC
Standard Practice.
of fireproofing shall be as specified on the design drawings.

15.

SHIPPING
The sizes of fabricated pieces shall be as large as practical considering means
of transportation between the fabricating shop and the site.
Small pieces shall be bundled with steel bands to prevent damage during
shipment and to facilitate unloading.
Loads shall not contain materials for more than one Material Requisition.
Bolts and nuts shall be shipped assembled, in clearly marked containers,
packed for each structure and colour coded to suit.

This document is company property. NAOC Ltd. lawfully reserves all rights. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited

CUSTOMER
NAOC
PLANT LOCATION
NAOC PH BASE - NIGERIA
PROJECT/UNIT
NEW PORT-HARCOURT BASE POWER
GENERATION PROJECT

Code: 3217.46.BASG.36908
Rev

Page 25 of 25

Steelwork members shall be shipped in erectable lots, i.e. columns shall be


shipped together with the connecting beams, bracing, connection cleats,
ladders, walkways, platforms, handrail, bolts, fastenings, etc. In the case of
multi-storey structures, the lower levels shall be shipped before the upper
ones. The lots shall be dispatched in erectable sequence.

This document is company property. NAOC Ltd. lawfully reserves all rights. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited