Date : May 27, 2010

MECIP (M) SDN BHD Rev : 0

MECIP Global Engineers Sdn Bhd Page : 1 of 11

DETAIL ENGINEERING DESIGN FOR SERVOCE PLATFORM

AT GPPB, PETRONAS GAS BERHAD

4.4 TECHNICAL SPECIFICATION FOR STRUCTURAL

STEELWORK

CONSULTANT OWNER
(PGB)
(MECIP)
REV DATE STATUS
Prepared Checked Approved Approved
By By By By

B0 25/05/10 Issued for Comment (IFC) SA MAL RBI

Approved for Construction

0 27/05/10 SA MAL RBI
(AFC)
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TABLE OF CONTENT

1.0 SCOPE 3

2.0 DEFINITION 3

3.0 CODES AND STANDARDS 3

4.0 MATERIALS 4

5.0 TEST AND INSPECTION 5

6.0 FABRICATING PRACTICES 6

7.0 WELDING AND FLAME CUTTING PROCEDURE MATERIALS 7

8.0 WELDING 8

9.0 TESTING 9

10.0 BOLTING 9

11.0 ERECTION 10
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1.0 SCOPE

1.1 This construction specification prescribes a guide for structural steelwork in PETRONAS
GAS BERHAD. The Contractor shall, supply, fabricate, and install all structural steel in
accordance with this specification and as shown on the drawings.

1.2 The work shall generally include, but not limited to the following:
 Supply of all structural steel.
 Supply of all bolts, base plate, metal grating and stair treads, including boarding
and fasteners, and all necessary steel items.
 Supply of mill certificates for structural steel.
 Preparation of steel surfaces.
 Detailed shop Drawings including bills of materials.
 Detailed erection Drawings, including field welds.
 Cleaning, priming, and/or galvanizing of all structural steel.
 Shop fabrication of all structural steel.
 Supply of all welding electrodes, filler wires and flux for shop fabrication.
 Field erection of all structural steel.
 Application of field coatings.

2.0 DEFINITION

Term “Owner” refers to PETRONAS GAS BERHAD and “Contractor” refers to the entity in charge
that will be appointed by Owner to execute the work.

3.0 CODES AND STANDARDS

This specification shall be read in conjunction with the following standards which are deemed to
form part of this specification. In the event of contradiction between this specification and the
standards, the requirement of this specification shall take precedence. Reference to any standard
shall include any amendment thereto:

Factories & Machinery Act, 1967 (Act 139) & Regulations Rules
Uniform Building By-Laws, 1984

PTS 34.00.01.30 Minimum Requirements for Structural Design Engineering

PTS 34.28.00.31 Steel Structures
BS 4 Structural Steel Sections
BS 709 Methods of Destructive Testing Fusion Welded Joints and Welds Metal in
Steel.
BS 729 Specification for Hot Dip Galvanized coatings on iron and steel articles.
BS 1449 Steel Plate, Sheet and Strip
BS 2894 Specification for Cold Rolled Steel Sections.
BS 3692 Specification for ISO Metric precision hexagon bolts, screws, and nuts,
Metric units.
BS 4190 Specification for ISO metric black hexagon bolts, screws, and nuts, Metric
units.
BS 4320 Specification for metal washer for general engineering purposes
BS 4360 Specification for Weldable Structural Steels
BS 4395 Specification for High Strength Friction Grip Bolts and Associated Nuts
and Washers for Structural Engineering
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BS 4604 Specification for the Use of High Strength Friction Grip Bolts in Structural
Steel Work
BS 4592 Industrial type metal flooring, walkways, and stair treads Part 1:
Specification for open bar gratings (1987 AMD1)
BS 4848 Hot Rolled Structural Steel Sections
BS 4870 Specification for approval testing of welding procedures
BS 4871 Specification for approval testing of welders working to approved welding
procedures
BS 4872 Specification for Approval Testing of Welders When Welding Procedures
Approval is not required
BS 5135 Specification for Arc Welding of Carbon and Carbon Manganese Steels
BS 5950 Structural Use of Steelwork in Building
BS 7613 Specification for Hot Rolled Quenched and Tempered Weldable Structural
Steel Plates
BS 7668 Specification for Weldable structural steels. Hot finished structural hollow
sections in weather resistant steels

4.0 MATERIALS

4.1 STRUCTURAL STEEL

All structural steel shall comply with the requirements of BS 4360 for Grades 43A, except
hollow sections which shall be Grade 43C. Hot rolled and cold rolled steel sections shall
comply with BS 4 and BS 2994 respectively and structural steel hollow sections to BS
4848: Part 2. Steel for cold rolled section shall also comply with BS 1449: Part 1.
Identification marks for the different grades of steel shall be provided in accordance with
BS 4360.

Minimum yield stress for structural steel shall be 275 N/mm2. For permissible stresses
see PTS 34.28.0031 Section 2.2.

4.2 ELECTRODES

Electrodes for metal arc welding shall comply with the requirements of BS EN
499.

4.3 BOLTS AND NUTS

All Structural bolts and nuts shall be of high strength Grade 8.8. Bolts shall comply with
BS 3692 except for the following minor connections where standard bolts (bolts grade
46) shall be used:
 Handrail connections
 Ladder connections
 Purlin
 Joist
 Walkways
 Stair treads
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4.4 WASHERS

All plain, tapered or other specially shaped washers shall be made of steel and shall
comply with the requirement of BS 4320.

4.5 SOLID PLATE FLOORING

Solid plate floor shall be checkered plate (6/8 thick). Floor plates shall be galvanized steel
plate.

5.0 TEST AND INSPECTION

5.1 INSPECTION

The Contractor shall request for the inspection of the work and facilities at all stages to
the Owner or to his Representative at Site. All work may be subjected to inspection
before delivery to the Site.

5.2 NOTICE

The Contractor shall give such reasonable notice to the Owner or his Representative of
the progress of the work as will enable the inspection, examination and testing as
required.

5.3 SAMPLES

Sample of materials and workmanship to be employed in the Works may be called for at
any time by the Owner Representative. Cost of providing and obtaining all samples shall
be deemed to be included in the rates entered in the Bill of Quantities.

5.4 WORK TEST

The Contractor shall arrange for all materials to be tested at the manufacturer’s work and
when required in the presence of the Owner’s Representative. When materials are
obtained from supplier stock, the Contractor shall be:
 By means of identification marks stamped on the materials together with the
manufacturer’s test certificates, show that such materials comply with the
requirements specified herein, or
 Arrange for samples to be taken and tested to prove the requisite quality. A copy of the
test certificates shall be submitted to Owner.

5.5 REJECTION

Nothing shall affect the right of Owner or their Representative to reject materials found
not suitable and do not comply with the specifications and requirements after delivery to
the site.

5.6 INDEPENDENT ANALYSIS AND TEST

The Owner reserves the right to require independent analysis and tests on the materials
by an Analysis or Testing Laboratory selected by him in order that a comparison of the
result of the two tests may be made. Should the result of any independent analysis or
test be unsatisfactory, the materials represented will be rejected.
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5.7 COST OF TEST

The costs of all analysis and tests made by manufacturers of made at work shall be
deemed to be included in the rates for steel work entered in the Bill of Quantities.

6.0 FABRICATING PRACTICES

6.1 MACHINING

For parts to be machined at least 3mm (0.12 in) in excess of the finished size or thick-
ness shall be allowed for machining.

6.2 NOTCHES

The ends of all joists, beams and girders shall be truly square where required, and joist
flanges shall be neatly cut away or notched where necessary, the notches being kept as
small as possible and well radius.

6.3 CUTTING

Cutting may be affected by shearing, cropping or sawing. The use of flame cutting shall
be subject to the Owner's approval. The edges of all plates shall be straight and fair
throughout. Sheared members shall be free from distortion.

6.4 HOLDING

Except where suitable templates are used, holes, through more than one thickness of
material shall be drilled after the members are assembled and tightly clamped together.
If the holes are punched separately before assembly, the holes shall be punched 3mm
(0.12in) less in diameter than the required size and reamed after assembly to the full
diameter, but the maximum thickness of materials Punched shall not be greater than
16mm (0.6 in).

All members shall be straight, free from twists, cracks, flaws, laminations, rouge jagged
and imperfect edges and other defects.

Holes for bolts shall not be formed by flame cutting process, except with specific
approval from the Owner Representative.

6.5 CONNECTIONS

All holes for strength grade 8.8 bolts shall be accurately marked off from template or
corresponding plate and shall be drilled. Holes shall be clear of bums or rough edges and
countersunk when required. Drifting shall not be allowed. The diameter of all holes shall
not exceed the diameter of the bolts by more than 1.5mm for bolts fewer than 20mm
and 2mm for bolts 20 mm and over.

Contractor shall provide all holes, indicated by the Drawings required for the installation
of equipment, drainage etc and shall furnish all erection bolts and washers including those
necessary to connect steelwork to other items. Beveled washers shall be provided for
sloped surfaces. All connections shall be strength grade 8.8 bolts unless welding or black
bolt grade 4.6 is required (see 5.3).
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 All connections shall have, as minimum, two bolts unless noted otherwise on
drawings.
 All field connections shall be by bolts. Field welding shall only be done under
exceptional circumstances. Contractor shall furnish and shop connects all erection
plates or angles required. All plates or angles to be field connected shall have
matching holes.
 Removable or non removable gratings shall be connected with a minimum of four
clips for panel as Manufacturer’s details.
 Care shall be taken to ensure that the clearances specified are adhered to. The
erection clearance for cleared ends of members connecting steel to steel shall not
be greater than 2mm at each end. The erection clearances of beams without web
cleats shall not be more than 3mm at each end.
 Where necessary, washers shall be tapered or shaped to give the heads and nuts
of bolts a satisfactory bearing. The threaded portion of each bolt shall project
beyond the nut by at least two threads.

7.0 WELDING AND FLAME CUTTING PROCEDURE MATERIALS

7.1 PROCEDURE TRIALS

When directed by the Owner or their Representative and before fabrication is

commenced, welding and flame cutting procedure trails shall be carried out using
representative samples of materials to be used in the work. The samples of materials
shall be selected and marked by the Owner or their Representative when the
materials for the works are inspected at the Subcontractor's workshop.

Trials on material 20mm (0.75 in) thick shall be taken to include all material up to but
not exceeding 20mm (0.75 in) thick. Trials on material 40mm (1.6 in) thick shall be
taken to include material over 20mm (0.75in) and up to but not exceeding 40mm (1.6
in) thick. Materials over 40mm (1.6 in) thick shall be tested for every thickness incre-
ment of 6mm (0.24 in).

The welding and flame cutting trials shall demonstrate to the satisfaction of the
Owner or their Representative the procedures to be adopted in the fabrication of the
work which shall include:
 Welding procedures in accordance with BS 5135 or AWS D1.1
 The heat control techniques required to ensure that the flame cut surfaces of
steel are free from cracks, local hardness and any other defects which would be
detrimental to the finished work.

The trials shall include specimen weld details representative of the actual construction
which shall be unfavorable conditions liable to occur in the particular fabrication. The
Contractor shall submit, prior to these trials, details of all welding procedures he
proposed to adopt, including those for repair, tack and attachment welds. Where primers
are to be applied to the work prior to fabrication, they shall be applied to the sample
material before the procedure trials are made. After the welding the specimens shall be
held at a temperature not less than 10°c (50°F) for a period not less than 72 hours and
shall then be sectioned and examined for cracks and other defects.
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7.2 GROUP OF TESTS

The following groups of tests to BS 709 shall be carried out:

 Butt Welds (are not allowed unless approved by the Owner Representative).
Transverse tensile test. Transverse and longitudinal bend tests. Separate tests shall
be performed in each case with the root of the weld in tension and compression
respectively.
 Fillet weld fracture test. Macro examination test.

8.0 WELDING

8.1 QUALIFICATION AND TESTING OF WELDERS

The Contractor shall provide to the Owner or their Representative satisfactory evidence
that the welders employed have passed the tests of BS 4872: Part 1 appropriate to the
work being performed.

Only skilled welding operators who satisfy the appropriate welding test specified therein
shall be employed. Notwithstanding compliance with the above requirements, the Owner
or their Representative reserves the right to have any welding operator retested at any
time and may require that his testing be carried out in his presence. All necessary
materials for these tests shall be provided by the Contractor free of costs.

8.2 SUPERVISION OF WELDING

Welding shall be carried out only under the direction of an experienced and competent
supervisor. Unless otherwise agreed by the Owner or their Representative a record shall
be kept to enable welds to be identified with the welders responsible for the work but
finished work shall not be marked by hard stamping for this purpose.

8.3 WELDING PLANT

The welding plant shall be capable of maintaining at the weld the voltage and current
specified by the manufacturer of the electrodes.

8.4 PROCEDURE

Metal-arc welding shall comply with BS 5135 or AWS D1.1. The Contractor shall submit to
the Owner complete details of the welding procedure to be adopted for each type and
size of weld for the components as applicable including details of necessary preheating
and post heating.

8.5 BUTT WELDS

Unless otherwise described in the Contract, all butt welds if allowed shall be complete
penetration welds made between prepared fusion faces. In the fabrication of built-up
assemblies, all butt welds in each component part shall be completed, wherever possible
before the final assembly. Where butt welds are to be ground flush there shall be no loss
of parent metal.
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8.6 ACCEPTANCE OF WELDED STRUCTURES

The acceptance of the welded work shall depend upon correct dimensions and alignment,
absence of distortion in the structure, satisfactory results from the examination and
testing of the joints and test specimens, soundness of the welds, and upon general good
workmanship. Defective welds shall be gouged out, rewelded and retested to the
approval of the Owner.

9.0 TESTING

9.1 GENERAL

The test shall be carried out in accordance with BS 709. The test results of welded joints
shall not be inferior, in any respect, to the British Standard test requirements for the
parent metal.

9.2 NON-DESTRUCTIVE TESTING (BUTT WELD)

The Contractor shall satisfy himself as to the quality of all butt welds by radiographic
inspection and shall submit the radiograph for examination by the Owner.

9.3 COSTS OF TEST

The cost of all testing including the supply of all materials and labor shall be borne by the
Contractor.

10.0 BOLTING

10.1 DIMENSIONS

Turned bolts shall have their shanks turned to the specified diameter, allowing a minus
tolerance of not more than 0.8mm (0.03 in) but no plus tolerance, so that a fumed bolt
will enter a hole of the same specified diameter as the bolt. All bolts shall have hexagonal
heads and nuts.

10.2 BOLTS

All bolts shall be high strength Grade 8.8. The nuts shall be a good fit on the bolts so that
they can only just be turned by hand and two clear threads shall show through the nut
when it has been finally tightened-up, every bolt unless otherwise specified shall be
provided with a washer under the nut.

10.3 WASHERS

Mild steel flat washers shall be circular of nominal outside diameter two times that of the
bolts. Where bolt heads or nuts bear upon beveled surfaces they shall be provided with
square taper washers of suitable thickness to afford a seating square with the axis of the
bolt.
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10.4 DESIGN AND DETAILING

All holes must be clear aligned to permit the bolts to be freely placed in position. The
driving of bolts is not permitted. The use of bolts, the permissible stresses, the size and
the pitch of the bolts shall comply with the requirements of BS 5950.

11.0 ERECTION

11.1 ERECTION SPECIFICATION

The Contractor shall ensure that all component parts of the structures will fit correctly
and that the holes of adjoining members correctly register with one another. The
Contractor shall temporarily erect at his Works such proportion of the component
parts as is necessary to verify to the satisfaction of the Owner the accuracy of
fabrication. The Contractor shall include in his rates all costs in respect of temporarily
erecting components. The provisions of all necessary flooring, staging, bolts and
everything necessary for test erection. The Contractor shall arrange for erection tests
to be witnessed by the Owner or his Representative if required.

11.2 ERECTION MARKS

Before any steelwork leaves the subcontractors Works, it shall be suitably marked in
accordance with the approved marking plans. The marks shall indicate the building,
the location within the building and the serial number of the member. Erection marks
shall be clearly painted at two positions on each member and all members weighting
over 5 tons shall have the weight marked thereon. The centre line of all columns,
beams, truss or beam bearings shall be described on the steel to ensure correct
alignment and assembly at Site.

11.3 STABILITY OF STRUCTURES

The Contractor shall be responsible for the stability of the structures at ail stages of
its erection on site and shall take all necessary measures by the addition of temporary
bracings and guying to ensure adequate stability.

11.4 SEATING (COLUMN BASES)

Column bases shall be set so that the column loading is uniformly transmitted to the
foundations. Where detachable bases are provided, provision shall be made to
support the base at a single central position during grouting.

11.5 GROUTING

The method of grouting to column bases shall be to the approval of the Owner or
their Representative and shall be such as to ensure a complete uniformity of contact
over the whole areas of the steel base.

11.6 ERECTION

No member of structure shall be finally bolted or welded until the whole or a major
section is approved by the Owner for line, levels and vertical alignment. Connections
shall be completed as soon as possible after receipt of the Owner's approval.
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11.7 CLEARANCE

In cases where owing to difficulties of erection, some clearance may be essential. This
clearance shall be a minimum allowance and fitting liners shall be avoided. The reaction
clearance for cleaned ends of members connected steel shall not be greater than 1.5mm
(0.05 in) unless specifically approved by the Contractor's Qualified Professional Engineer.

11.8 TOLERANCE

The tolerance for the erected steel work shall be as follows:

 Permissible deviation of the erected column from its specified position is ±5mm
 Permissible deviation from specified length or width per 10m of length is ±5mm
 Permissible deviation from verticals per 15m of height is ±15mm
 Unless otherwise specified the level of a beam should be taken on the top of the
upper flange. Permissible deviation between the specified level and that of the
erected member is ±3mm

11.9 TIGHTENING OF HIGH STRENGTH FRICTION GRIP BOLTS

Where high strength friction grip bolts are specified, they shall be of the loading
indication type such that achievement of the proof tensile load can be directly related to
feeler gauge measurement of gap closures on the bolt head or on the washer. The
Contractor shall submit to the Owner for their approval the type of load indicating system
be wishes to use and also the load indicating bolt or load indicating washer
manufacturer.

The surfaces in contact shall be free of paint or any other applied finish, oil, dirt, loose
scale, burns and other defects which would prevent solid seating of the parts or would
interfere with the development of friction between them.

12.0 PAINTING

Except for galvanized steel, surfaces of all elements and/or pieces which from steel schedules
shall be prepared and primerized according to the PTS 30.48.00.31 Gen. Requirements.

13.0 FIRE PROOFING (if applicable)

Fire proofing of structural steel shall comply with relevant specification for fire proofing. Structural
members to be fire protectors shall be clearly indicate on shop drawings. Such members shall be
supplied with surface preparation and shop priming only in accordance with painting specification.