SECTION 05120 STRUCTURAL STEEL

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK This specification covers the requirements for the supply, detailing, fabrication, shop inspection, shop testing, shop painting, and delivery to job site of all structural steel for the Steam Plant. Structural steel is that work defined in the AISC "Code of Standard Practice" and as otherwise shown on the drawings. Related Work: 1. 2. 3. 1.2 Section 03300: Cast-In-Place Concrete Section 05500: Metal Fabrications Section 09900: Painting

B.

B.

QUALITY ASSURANCE a. Codes and Standards: Comply with the applicable pro-visions of the following codes and standards, except as otherwise shown and specified: 1. 2. AISC "Code of Standard Practice for Steel Buildings and Bridges." AISC "Specifications for the Design, Fabrication, and Erection of Structural Steel for Buildings," including "Commentary of the AISC Specifications" and supplements thereto. AISC "Specifications for Structural Joints Using ASTM A325 or A490 Bolts" approved by the Research Council of Riveted and Bolted Structural Joints of the Engineering Foundation. AWS D1.1 "Structural Welding Code." American Society for Testing and Materials (ASTM) standard as specified in this section and including ASTM A6 "General Requirements for Delivery of Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use."

3.

4. 5.

b. Qualifications for Welding Work: 1. Qualify welding procedures, welders, and welding operators in accordance with AWS D1.1 "Structural Welding Code."

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Provide certification that welders to be employed in the work have satisfactorily passed AWS qualification tests within the previous 12 months. If recertification of welders is required, retesting will be the Contractor's responsibility.

3.

C.

Fabrication Quality Control: 1. Materials and fabrication procedures shall be subject to inspection and tests in the mill, shop, and all field tests shall be done by an independent testing laboratory. Such inspections and tests will not relieve the Contractor of responsibility for providing materials and fabrication procedures in compliance with specified requirements. Inspection and testing for structural steel: Testing and inspection of structural steel will be performed by a testing laboratory for compliance with the specified materials. Inspection and testing for bolt connections: Bolted connections will be inspected in accordance with AISC 314 and as shown. Inspection and testing for welding: Welding will be field inspected and tested by an independent testing laboratory during fabrication and erection of structural steel as follows: c. Certify all welders and make inspections and tests as required. Record types and locations of all defects found in the work, the measures required and performed to correct such defects. In addition to visual inspection of all welds, magnetic particle, ultrasonic, and radiographic inspection will be made of all welds as specified. The method of magnetic particle inspection will be in accordance with ASTM E109. Magnetic particle inspection will be made on root pass and finished welds. Any type of crack or zone of incomplete fusion or penetration will not be acceptable. Magnetic testing need not be performed when welding clips and other attachments to structural steel members. Radiographic inspection technique and standards of acceptance will be in accordance with AWS D1.1 and comply with ASTM E94 and E142; minimum quality level "2-2T2." Radiographic inspection shall be done on all butt weld/splices where the principal stress is transverse to the weld. Ultrasonic inspection will be performed in accordance with AWS D1.1 and comply with ASTM E164. Ultrasonic testing shall be done on 10% of full penetration corner groove welds.

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g.

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Welder Identifying Symbols: Each bolting crew and welder shall be assigned an identifying symbol or mark and all shop and field connections shall be so identified so that the inspector can refer back to the crew or person making the connection. Testing Laboratory: The testing laboratory shall be responsible for conducting and interpreting the tests, shall state in each report whether or not the test specimens conform to all requirements of the specifications and shall specifically note any deviations therefrom. Repair and Reinspection of Welds: Repair defective welds in accordance with AWS D1.1, Article 3.7; or replace the weld, and reexamine repaired and replaced welds by the method used to examine the original weld. In addition, when defective welds are found, the testing laboratory shall determine the cause of the defective welding and institute immediate corrective action.

i.

j.

D.

Design of Members and Connections: 1. All details shown are typical; similar details apply to similar conditions, unless otherwise indicated. Verify dimensions at the site whenever possible without causing delay in the work. Promptly notify the MARAFIQ whenever design of members and connections for any portion of the structure are not clearly indicated.

2.

1.3 A.

SUBMITTALS Product Data: Submit copies of producer's or manufacturer's specifications and installation instructions for the following products. Include laboratory test reports and other data as required to show compliance with these specifications. 1. Structural steel (each type), including certified copies of mill reports covering the chemical and physical properties. High-strength bolts (each type), including nuts and washers. Unfinished bolts and nuts. Structural steel primer paint. Shrinkage-resistant grout.

2. 3. 4. 5. B.

Shop Drawings: 1. Submit shop drawings including complete details and schedules for fabrication and shop assembly of members, and details, schedules, procedures and diagrams showing the sequence of erection.

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MARAFIQ's review of shop drawings will be for general considerations only. Compliance with requirements for materials fabrication and erection of structural steel is the Contractor's responsibility. a. Include details of cuts, connections, camber, holes, and other pertinent data. Indicate welds by standard AWS A2.0 "Welding Symbols," and show size, length, and type of each weld. Provide setting drawings, templates, and directions for the installation of anchor bolts and other anchorages to be installed by others.

b.

1.4 A.

DELIVER, HANDLING, AND STORAGE Deliver materials to the site at such intervals to insure uninterrupted progress of the work. Do not handle steel until primer coats of paint are dry. Take care to prevent abrasion of applied coatings. Deliver anchor bolts and anchorage devices, which are to be embedded in castin-place concrete or masonry, in ample time to not delay that work. Store materials to permit easy access for inspection and identification. Keep steel members off the ground, using pallets, platforms, or other supports. Protect steel members and packaged materials from corrosion, deterioration, and inclement conditions. Do not store materials on the structure in a manner that might cause distortion or damage to the members or the supporting structures. Repair or replace damaged materials and structures as directed.

B.

C.

D.

PART 2 - PRODUCTS 2.1 A. B. C. MATERIALS Steel plates, Shapes, and Bars: ASTM A36, unless other-wise shown. Cold-formed Steel Tubing: ASTM A500, Grade B. Hot-formed Steel Tubing: ASTM A501, welded or seamless, including square rectangular, round, and special shapes. Steel Pipe: ASTM A53, Type E or S, Grade B. Carbon Steel Castings: ASTM A27, Grade 65-35, medium-strength carbon steel. Anchor Bolts: ASTM A307, non-headed type, unless otherwise indicated. Unfinished Bolts: ASTM A307, regular hexagon-bolts with nuts low carbon steel and washers conforming to ANSI B18.2.2.1, Type B unless otherwise shown. Anchor bolts shall be non threaded type, except where otherwise shown.
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D. E.

F. G.

H.

Headed Stud Type Shear Connectors: ASTM A108, Grade 1015 or 1020, cold finished carbon steel; with dimensions complying with AISC Specifications. High-strength Bolts and Nuts: ASTM A325 or A490, heavy hexagonal structural bolts with nuts and hardened washers. Electrodes for Welding: Comply with AWS A5.1, E70 XX Series, as required for intended use. Primer Paints: Provide shop applied paint primers for structural steel complying with SSPC paints as follows. Primers shall be compatible with finish coats as required. 1. SSPC -Paint 14, red lead, iron oxide and linseed oil for rust inhibitive protection and weather-ability, slow drying.

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K.

B.

Cement Grout: Portland cement, complying with ASTM C150, Type II. Provide clean, uniformly graded, natural sand complying with ASTM C404, Size No. 2. Mix at a ratio of 1 part cement to 3 parts sand, by volume, with only the minimum amount of water required for placement and hydration.

M.

Non-metallic Non-shrink Grout: Pre-mixed, non-metallic, non-corrosive, nonstaining product containing selected silica sands, portland cement, shrinkage compensating agents, plasticizing and water reducing agents, complying with CRD-588. SHOP FABRICATION General: 1. Fabricate and assemble structural assemblies in the shop to the greatest extent possible. Fabricate items of structural steel in accordance with these specifications, referenced standards, and as indicated on approved shop drawings. Provide camber in structural members as shown. Properly mark and match-mark materials for field assembly. Fabricate for delivery sequence which will expedite erection and minimize field handling of materials. Where finishing is required, complete the assembly, including welding of units, before start of finishing operations. Provide finish surfaces of members exposed in the final structure free of markings, burrs and other defects. Milling and Planning: Mill column and bearing stiffeners to give full bearing over the cross section. Plane contact surfaces of bearing plates. Planning of bottom surfaces of plates of grout beds is not necessary.

2.2 A.

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Drilling and Punching: Drill or punch holes at right angles to the surface of the metal, not more than 2 mm larger than the connector diameter. Do not flame cut holes or enlarge holes by burning. Drill steel having a thickness in excess of the connector diameter, material thicker than 22 mm and steel bearing plates. Holes shall be clean-out without torn or ragged edges. Remove outside burrs resulting from drilling operations. Holes, Slots, and Openings: Provide holes, slots, and openings required by other work together with necessary reinforcing as shown. Use suitable templates for proper locations of these openings. Steel requiring adjustment shall be provided with slotted holes as shown. No change in location of openings will be permitted without prior approval.

6.

B.

Shop Connections: 1. Shop connections shall be welded or bolted as indicated. Connections shall be with high-strength bolts, unfinished bolts, and welds as shown on accepted shop drawings. Minimum connections shall comply with appropriate tables for "Framed Beam Connections" shown in the AISC "Manual of Steel Construction." Seated connections may be used only when they do not interfere with architectural features. Non-composite Beam Connections: For non-composite beams, the connections used shall be adequate to provide for the reaction due to the maximum uniformly distributed load that the beam is capable of carrying for its span, based on the allowable unit stresses, except where higher reactions are shown or specified. Composite Beam Connections: For composite beams, connections shall be adequate to provide for reactions shown.

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C.

Bolting: 1. Bolts shall be of length that will extend not less than 6 mm beyond the nuts. Enter bolts into holes without damaging the thread. High-Strength Bolts: Use high-strength bolts in bearing and friction connections and as otherwise shown. Install high-strength bolts in accordance with AISC "Specifications for Structural Joints using ASTM A325 or A440 Bolts." a. Make high-strength bolted joints without the use of erection bolts. Bring members tightly together with sufficient high-strength "fittingup" bolts which shall be retightened as all the bolts are finally tightened. Protect bolt heads from damage during placing. Bolts that have been completely tightened shall be marked for identification.

2.

b.

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The contact surfaces in high-strength bolted connections shall be exposed steel free of rust, oil, paint, lacquer, or other coatings. Final tightening of high-strength bolts shall be by turn-of-nut method unless properly calibrated wrenches are specifically required. Each wrench shall be checked for accuracy at least once daily.

d.

3.

Unfinished Bolts: Use unfinished bolts in locations where high-strength bolts are not shown or specified to be used. Draw unfinished bolt heads and nuts tight against the work with a suitable wrench. Peen bolt threads for unfinished bolts to prevent the nuts from backing off. Comply with the inspection and testing requirements for bolting specified in article "Quality Assurance" of this Section.

4.

D.

Welding: 1. Comply with AWS D1.1 for procedures, appearance and quality for welds, inspection and test methods used in connecting and fabricating welded work. Do not begin structural welding until joint elements are bolted or tacked in intimate contact and adjusted to dimensions shown with allowance for any weld shrinkage that is expected. Weld heavy sections and those having a high degree of restraint with low hydrogen type electrodes. No members are to be spliced without approval. Assemble and weld built-up sections by methods which will produce true alignment of axes without warp. Comply with the inspection and testing requirements for welding specified in article "Quality Assurance."

2.

3.

4.

E.

Shear Connectors: 1. 2. Prepare steel surfaces as recommended by the shear connectors. Shop weld shear connectors, spaced as shown, to beams and girders in composite construction. Use automatic end welding of headed stud shear connectors in accordance with the manufacturer's printed instructions.

3.

F.

Steel Wall Framing: 1. Select members which are true and straight for the fabrication of steel wall framing. Straighten as required to provide uniform, square and true members in the selected wall framing. Build-up welded door frames attached to structural steel framing. Weld exposed joints continuously and grind smooth. Plug weld steel bar stops
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to frames, except where shown removable. Secure removable stops to frames with countersunk, cross-recessed head machine screws, uniformly spaced not more than 250 mm on-center unless otherwise shown. G. Shop Prime Painting: 1. Shop prime paint all structural steel work, except those members or portions of members to be embedded in concrete or mortar and surfaces to be field welded, surfaces to receive spray-on fireproofing, surfaces penetrated to receive bolting, and top portions of steel flanges to receive shear connectors. After inspection and before shop painting, clean steel work. Remove loose rust, loose mill scale, and spatter, slag, flux deposits, oil, and grease. Clean steel in accordance with SSPC specifications as follows: a. 3. SP-6 "Commercial Blast Cleaning"

2.

Within 4 hours after surface preparation, apply structural steel primer paint at a rate to provide a uniform dry film thickness of 0.50 mm per coat. Use painting methods which will result in full coverage of joints, corners, edges, and all exposed surfaces. Apply one shop coat to structural steel members, except apply two coats of paint to surfaces which are inaccessible after assembly or erection. Change color of second coat to distinguish it from the first.

4.

PART 3 - EXECUTION 3.1 A. INSPECTION Examine the areas and conditions under which structural steel work is to be installed. Do not proceed with the work until unsatisfactory conditions have been corrected in an acceptable manner. ERECTION Temporary Shoring and Bracing: Provide temporary shoring and bracing members with connections of sufficient strength to bear imposed loads. Remove temporary members and connections when permanent members are in place and final connections are made. Temporary Planking: Provide temporary planking and working platforms as necessary to effectively complete the work. Anchor Bolts: Furnish anchor bolts and other connectors required for securing structural steel to foundations and other in-place work.

B.

3.2 A.

B.

C.

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Furnish templates and other devices as necessary for presetting bolts and other anchors to accurate locations. Refer to Section 03300 of these specifications for anchor bolt installation requirements in concrete, and Section 04200 for masonry installation.

2.

D.

Setting Bases and Bearing Plates: Clean concrete and masonry bearing surfaces of bond-reducing materials and roughen to improve bond to surfaces. Clean the bottom surfaces of base and bearing plates. 1. Set loose and attached base plates and bearing plates for structural members on wedges or other adjusting devices. Tighten the anchor bolts after the supported members have been positioned and plumbed. Do not remove wedges or shims, but if protruding, cut off flush with the edge of the base or bearing plate prior to packing with grout. Pack grout solidly between bearing surfaces and bases or plates to ensure that no voids remain. Finish exposed grouted surfaces. Protect installed material, and allow grout to cure in strict compliance with the manufacturer's instructions.

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3.

E.

Field Assembly: 1. Set structural frames accurately to the lines and elevations indicated. Align and adjust the various members forming a part of a complete frame or structure before permanently fastening. Clean bearing surfaces and other surfaces which will be in permanent contact before assembly. Perform necessary adjustments to compensate for discrepancies in elevations and alignment. Level and plumb individual members of the structure within specified AISC tolerances. Establish required leveling and plumbing measurements at the mean operating temperature of the structure. Make allowances for the difference between temperature at time of erection and the mean temperature to which the structure will be subjected once completed and in service. Splice members only where shown or specified.

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6. F.

Erection Bolts: On exposed welded construction, remove erection bolts, fill holes with plug welds, and grind smooth at exposed surfaces. Comply with AISC Specifications for bearing, adequacy of temporary connections, alignment, and the removal of paint on surfaces adjacent to field welds.
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G.

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Do not enlarge unfair holes in members by burning or by the use of drift pins, except in secondary bracing members. Ream holes that must be enlarged to admit bolts.

H.

Gas Cutting: Do not use gas cutting torches in the field for correcting fabrication errors in the structural framing. Cutting will be permitted only on secondary members which are not under stress, as acceptable to the MARAFIQ. Finish gas-cut sections equal to a sheared appearance when permitted. FIELD CONNECTIONS Field connections shall be welded or bolted as indicated. Connections shall be with high-strength bolts, unfinished bolts, and welds as shown. Minimum connection shall comply with appropriate tables for "Framed Beam Connections" shown in the AISC "Manual of Steel Construction." Seated connections may be used only when they do not interfere with architectural features. Bolting: 1. Bolts shall be of length that will extend not less than 6 mm beyond the nuts. Enter bolts into holes without damaging the thread. High-Strength Bolts: Use high-strength bolts in bearing and friction connections and as otherwise shown. Install high-strength bolts in accordance with AISC "Specifications for Structural Joints using ASTM A325 or A440 Bolts." a. Make high-strength bolted joints without the use of erection bolts. Bring members tightly together with sufficient high-strength "fittingup" bolts which shall be retightened as all the bolts are finally tightened. Protect bolt heads from damage during placing. Bolts that have been completely tightened shall be marked for identification. The contact surfaces in high-strength bolted connections shall be exposed steel free of rust, oil, paint, lacquer, or other coatings. Final tightening of high-strength bolts shall be by turn-of-nut method unless properly calibrated wrenches are specifically required. Each wrench shall be checked for accuracy at least once daily.

3.3 A.

B.

C.

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b.

c.

d.

3.

Unfinished Bolts: Use unfinished bolts in locations where high-strength bolts are not shown or specified to be used. Draw unfinished bolt heads and nuts tight against the work with a suitable wrench. Peen bolt threads for unfinished bolts to prevent the nuts from backing off.

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Welding: 1. Comply with AWS D1.1 for procedures, appearance and quality of welds, inspection and test methods used in connecting and fabricating welded work. Do not begin structural welding until joint elements are bolted or tacked in intimate contact and adjusted to dimensions shown with allowance for any weld shrinkage that is expected. Weld heavy sections and those having a high degree of restraint with low hydrogen type electrodes. No members are to be spliced without approval. Assemble and weld built-up sections by methods which will produce true alignment of axes without warp.

2.

3.

E.

Shear Connectors: Replace bent, broken, and severed shear connectors with new connectors applied by welding. FIELD QUALITY CONTROL Provide access by the MARAFIQ and testing laboratory's representatives to locations where structural steel work is being fabricated or produced. The MARAFIQ reserves the right, at any time before final acceptance, to reject material fabricated work not complying with specified requirements. Correct deficiencies in structural steel work which inspections and laboratory test reports indicate does not comply with specified requirements. Perform additional tests as may be necessary to show compliance of corrected work. Shop Welding: Comply with the inspection and testing requirements for welding specified in article "Quality Assurance." Field Bolted Connections: Comply with the inspection and testing requirements for bolting specified in article "Quality Assurance." Bolt field connections, except where welded connections or other connections are specifically indicated. PAINTING Touch-Up Painting of Prime Shop Coat: 1. Immediately after erection, clean field welds, bolted connections, and abraded areas of loosened shop paint. Apply field paint to exposed steel surfaces using the same material as used for shop painting. Apply by brush or spray to provide a minimum dry film thickness of 0.050 mm.

3.4 A.

B.

C.

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3.5 A.

2.

B.

Finish Painting: Finish painting of structural steel scheduled to be field painted shall receive finish paint and coats complying with Section 09900. + + END OF SECTION 05120 + +
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