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Sarcheshmeh Flash Smelting Furnace Project

Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

Page 1 of 36

Specification for fabrication and erection of steelwork

SPECIFICATION FOR FABRICATION AND ERECTION OF STEELWORK

01 00
REV.

26 July 2011 14 Apr 2011


DATE

Issued for Construction Issued for Approval


DESCRIPTION

IFC IFA
PURPOSE OF ISSUE

S.J S.J
PREPARED

B.GH B.GH
CHECKED

H.M H.M
APPROVED

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

Revision Index
Sheet No. 00 01 Rev. Sheet No. 00 Rev 01 Sheet No. 00 01 Rev.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

x x x x x x x x x x x x x x x x x x X x x x

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

x x x x x x x x x x x x x x x x x

35

X X

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

Table of Contents
1.0 GENERAL 1.1 PROJECT OVERVIEW 1.2 DOCUMENT SCOPE 1.3 DEFINITIONS 2.0 MATERIALS 2.1 2.2 2.3 2.4 2.5 MATERIAL REQUIREMENTS STRUCTURAL SHAPES, PLATES AND BARS PIPE COLUMNS AND HANDRAIL HIGH STRENGTH BOLT ASSEMBLIES STANDARD BOLT ASSEMBLIES STANDARD BOLT ASSEMBLIES 2.6 WELDING FILLER METAL 2.7 OPEN GRID FLOORING 3.0 FABRICATION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 GENERAL SHOP AND ERECTION DRAWINGS DETAILS CONNECTIONS CONNECTIONS GRATING PLATE FABRICATION TOLERANCES HANDLING, SHIPPING, DELIVERY AND STORAGE 6 6 6 6 6 7 7 7 7 72.5 8 8 8 8 8 8 9 93.4 10 10 11 11 13 13 13 14

4.0 ERECTION 4.1 GENERAL 4.2 TEMPORARY SUPPORTS OF STRUCTURAL STEEL FRAMES

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

4.3 SETTING BASE PLATES 4.4 FIT UP CONNECTION 4.5 CORRECTION OF ERRORS 4.6 ERECTION AND SHOP DRAWINGS 4.7 SAFETY 4.8 ASSEMBLY LIFT PLAN 4.9 ERECTION TOLERANCES 4.9.1 COLUMNS 4.9.2 MEMBERS CONNECTING TO COLUMNS 4.9.3 OTHER MEMBERS 4.9.4 ADJUSTABLE ITEMS 5.0 BOLTED PARTS REQUIREMENTS 5.1 GENERAL 5.1.1 SCOPE 5.2 MATERIAL 5.3 BOLTED PARTS 5.4 BOLT HOLES 5.4.1 GENERAL 5.4.2 PUNCHED HOLES 5.4.3 REAMED OR DRILLED HOLES 5.4.4 ACCURACY OF HOLES 5.4.5 ACCURACY OF HOLE GROUP 5.4.5.1 Accuracy Before Reaming 5.4.5.2 Accuracy After Reaming 5.5 INSTALLATION 5.5.1 GENERAL 5.5.2 REQUIREMENTS FOR WASHERS 5.5.3 TURN-OF NUT TIGHTENING 5.5.4 CALIBRATED WRENCH TIGHTENING 5.5.5 DIRECT TENSION INDICATOR TIGHTENING 5.5.5.1 Verification 5.5.5.2 Installation 6.0 WELDING PROCEDURE & REQUIREMENTS

14 14 15 15 15 16 16 16 17 17 17 17 17 17 18 18 18 18 19 19 19 19 19 19 20 20 22 23 23 24 24 26 26

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

6.1 GENERAL 6.1.1 SCOPE 6.1.2 APPLICATION 6.2 WELDING PROCEDURE SPECIFICATION (WPS) 6.3 WELDING PROCEDURE QUALIFICATION TEST (WPQT) 6.4 WELDING ELECTRODES AND CONSUMABLES 6.5 PREPARATIONS FOR WELDING 6.5.1 WELDING PROGRAM 6.5.2 VERIFICATIONS BEFORE WELDING WORKS 6.5.3 PREPARATION FOR CHAMFERING 6.5.4 SURFACE CONDITIONS 6.5.5 PRE-HEATING 6.5.6 INTER-PASS-TEMPERATURE 6.6 EXECUTION OF WELDING WORKS 6.7 INSPECTION AND TESTING 7.0 FIELD PAINTING 7.1 STANDARD 7.2 DAMAGED AREAS 7.3 FIELD INSPECTION

26 26 27 27 27 27 27 27 29 29 29 29 30 30 30 31 31 31 31

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

1.0 1.1

General PROJECT OVERVIEW

Construction on EPC basis of Flash Smelter Furnace Sarcheshme Copper Complex being located at 50 km west of Sarcheshmeh Kerman and 30 km east from Shahr Babak city at Kerman Province, Iran, with the steady production capacity of 875 ton per day Cathodic copper production with the technical documents and specifications and conditions mentioned in the project documents. Including of basic engineering review, detail engineering, site engineering, Material supply (Foreign / local), manufacturing / inspection, packing, insurance covering, site fabrication, all construction activities including of Civil works, Equipment erections & test, pre-commissioning, test performance, client personnel training, 2 years spare parts supply for operation, consumable material supply for 12 month operation, supervision on operation for 6 month.

1.2

DOCUMENT SCOPE

This standard covers the minimum requirements for Sarcheshmeh Flash Smelting Plant of the fabrication and erection of steel framing for buildings, steel structures supporting equipment, steel yard supports and miscellaneous structural steel, such as steel platforms, stairs, ladders, grating, walkways, stanchions, trolley beams, crane rails, railing, etc. All work shall be completed in accordance with engineering codes and standards listed in document: civil design criteria (418/200-000-C1-001) Where there are national regulations, their particular requirements, and those of the standards and codes to which they refer, must be applied, supplementing or amending the provisions of this document 1.3 DEFINITIONS

Employer: National Iranian Copper Industries Co.(NICICO) M.C: Non-ferrous Industries Process Engineering and Construction (NIPEC) Contractor: Sadid Jahan Sanat, Bam Rah, Fakoor Sanat Teharn, Sanayea-E-Madani Mobina Tekjoo

2.0

MATERIALS

Equivalent materials, grades and shapes can be proposed by CONSTRUCTION CONTRACTOR and shall be subject to prior COMPANY approval. CONSTRUCTION CONTRACTOR shall demonstrate the equivalence on a standard basis.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

2.1

Material Requirements

All material shall be of new stock, without damage and in conformance to the specification for structural steel. A minimum thickness of 6mm shall be considered for any part of Built up structural shapes constituting main structural frames of steel pipe racks, steel structures, heavy pipe supports and shelters. The minimum thickness of plate material used for structural connections shall be 8 mm. Where contact of dissimilar metals will cause galvanic action or corrosion, a suitable insulating material shall be provided between the metals. Structural steel pipe shall be limited to seamless or electric-welded, straight-seam pipe. Where steel pipes or tubing are used, all open ends shall be sealed to prevent internal corrosion. Lamination test should be done for plates with thickness more than 25 mm. 2.2 Structural Shapes, Plates and Bars

Structural steel shall be Grade ST-37 in accordance with DIN 1025, 1050 or ASTM A36 All structural steel shall have certificate. Materials without certificate shall be checked for chemical & physical properties by a certified laboratory.

2.3

Pipe Columns and Handrail

Pipe for columns or handrail shall be as per ASTM A53 Type E or S, Grade B or API Standard 5L, Grade B.

2.4 Bolt

High Strength Bolt Assemblies ASTM A325M Type1, ASTM A490M Type1 or DIN 7990 & DIN 555

Washer Direct Tension Indicator Washer Heavy Hex Nut

ASTM F436M.,equivalent to DIN 7989 F959M. ASTM 563M Grade C3 DH3, A194M GR 2H or DIN 555 .

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

2.5 Bolt

Standard Bolt Assemblies ASTM A307 Grade A and C, Heavy Hex. ASTM F436. ASTM A563 Grade A or Din 555.

Washer Heavy Hex Nut

2.6

Welding Filler Metal

Welding Electrodes for manual shield metal-arc welding shall be E60XX and/or E70XX in accordance with requirements of AWS D1.1 and AWS A.5.1, section 4.1

2.7

Open Grid Flooring

Open grid flooring and stair treads shall be as per ASTM A36 / A36M, galvanizsed as per ASTM A153 A123 Grade 60. The top surface of bearing bars shall be serrated type. Grating stair treads shall have abrasive nosing

3.0 3.1

FABRICATION General

All fabrication shall be in accordance with the AISC Specification for Structural Steel Buildings AISC 360-05 and Codes of Standard Practice for Steel Buildings and Bridges AISC 303-10 Frames, platforms, stairs and handrails shall be shop assembled in the largest units suitable for handling and transportation. Field connections will be preferably reduced to a minimum. Sections or assemblies too long for shipment shall be provided with field joints of the same member strength. All beams, except cantilevers, shall be fabricated with natural mill camber in the up position. All pieces shall be clearly marked with permanent identifying erection mark numbers.

3.2

Shop and Erection Drawings

The CONSTRUCTION CONTRACTOR shall produce shop and erection drawing for the fabrication and erection of structural steel in accordance with design drawings and standards and is responsible for the following: a) The transfer of information from the contract documents into accurate and complete shop and erection drawings

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

b) The development of accurate, detailed dimensional information to provide for the fit-up of parts in the field. Each shop and erection drawing shall be identified by the same drawing number throughout the duration of the project and shall be identified by revision number and date, with each specific revision clearly identified. All the welding shall be done at shop. Steel work that is to be site welded shall be clearly indicated on shop drawings. CONSTRUCTION CONTRACTOR shall furnish checked shop detail drawings for review by the COMPANY. Shop drawings shall include all fabrication and erection details and complete detailed bolt lists, procedures, and diagram showing sequence of erection and specifying bolted and welded connections in accordance to Contract document and detail drawing. Review of drawings by the COMPANY shall be for general conformance with the Contract Documents only. CONSTRUCTION CONTRACTOR shall take full responsibility for the correctness of details, dimensions, materials, and fabrication. Shop details shall be in strict accordance with Design Drawings, When the CONSTRUCTION CONTRACTOR submits a request to change connection details that are described in the contract documents/design drawing, the CONSTRUCTION CONTRACTOR shall notify t he owners designated representatives for design and construction in writing in advance of the submission of the shop and erection drawings. The owners designated representative for design shall review and approve or reject the request in a timely manner. The CONSTRUCTION CONTRACTOR shall also prepare an Erection Procedure to include a list and numbering system for all the individual steelwork elements in timely manner to properly plan and perform the work.

3.3

Details

All holes placed in steel material shall be drilled or punched. Do not flame cut bolt holes or enlarge holes by burning or gas flame Splicing shall only permitted where shown on shop drawing. Grouting holes in base plate shall be foreseen. Flame cut of plates and shapes is not allowed, unless the cut edge which is damaged due to heat is sawed. Solid floor plates shall be detailed on shop drawings. Gaps between panels shall be 6 mm as a maximum. Every side of each panel shall be supported on structural framing. Solid floor plates shall be shop welded or field bolted on framing. Removable panels shall be bolted to structural framing using countersunk flat head bolts. Removable panels shall be arranged in panels, each weighing less than 45 kg. Floor grating panels shall be less than 65 kg

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

3.4

Connections

Bolts and Washers of all types and size required shall be provided for completion of all field erection. Type of all Bolted connection shall be specified in shop drawing as snug tightened or slip critical in strict accordance to design drawings. Faying Surfaces and surface adjacent to the bolt head and nut shall be free of dirt and other foreign material. Type of faying surface for slip critical connection shall be Class A as AISC specified specification for structural steel except pre-qualified type of end plate connection. All structural strength welding shall be continuous. Parts to be welded shall be carefully prepared. Alignment, jigging and welding sequences shall be such as to minimize deformations and residual stress. Edge beveling of Pprepared weld profiles shall be checked by gauges before welding. Welding procedures shall be prepared and tested in accordance with AWS D 1.1. Use of pre-qualified procedures will be acceptable, provided that certified test results showing conformance to specification requirements are submitted to and approved by the COMPANY. Welding procedures shall identify material, weld geometry, tolerances, welding process, pre-heat temperature and welding position to be used. Field connections for random-length materials of handrail and ladder cage assemblies shall be welded. Continuous seal welding shall be used in places that are not self-draining or where crevice corrosion is likely to occur. If seal welding is not practical, alternative methods of sealing shall be used with the approval of the COMPANY 3.5 Grating

Fabrication of grating, safe working loads and allowable deflections shall be according to standard detail drawings (418/200-D00-T3-004). Steel gratings shall be a 30X50mm mesh, with bearing bars 30X3mm and transverse deformed bar 6mm. Steel shall be in compliance with ASTM A36 or approved equivalent. ALL Gratings shall be plate to plate type with min. thickness of 3 mm for plates. Grating shall be hot-dip galvanized in accordance with ASTM A153A123, with the average weight of the zinc layer of 550 gr/m2 of galvanised surface, with a minimum of 500 gr/m2. unless specified otherwise on design drawing. If a galvanized coating is damaged, the area shall be thoroughly cleaned free of grease, oil and other foreign matter and shall be dry. It shall then either be blast cleaned to white metal in accordance with SSPC-SP5/NACE No. 1, or prepared to the same standard, using mechanically operated tools. Then the coating to the clean and dry surface by means of metalspraying pistols fed with either zinc wire or zinc powder should be applied as soon as possible after surface preparation and before visible deterioration of the surface has occurred. and following two coats of zinc- rich (minimum 92 wt%). Epoxy paint shall be applied to give a total dry film thickness of at least 150 micron, considering that the zinc-rich paint shall be applied in accordance with section c following:

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

When during construction maintenance, cutouts or repairs by flame have to be made or surface area have to be prepared, grating shall be removed to a remote safe area to avoid that molten zinc attack on stainless steel piping and/or equipment. Grating parts will be provided with end bars. Grating shall be spliced near cutouts, as indicated on design drawings and shall be provided with end bars. A steel band will trim unsupported bearing bars. Toe plate will be welded to grating holes and cutouts. Toe plate will not be welded to grating, where hand railing is connected to platform beams. Fixation Grating panels shall be clamped to structural steel with a minimum of 4 bolted clamps. At large grating panels, minimum 4 panel clamps per square meter to be provided. These fixing devices shall be hot-dip galvanized. Minimum clearance for a pipe through grating shall be provided using the greatest of the following hole diameters: Diameter of hole is pipe diameter+ insulation + 50mm or Diameter of hole is flange diameter + 25mm

3.6

Plate

Raised Pattern Plate 6/8 mm thickness shall be used unless otherwise indicated in the drawings. Raised pattern plates shall be attached by means of intermittent welds to support steel (except where otherwise noted on design drawings). One drainage hole 15mm for every 2.0 m2 of floor plate shall be drilled after erection at low spots, with a minimum of one hole per panel. Removable floor panels shall not be locked in position by piping conduits or other equipment. Removable sections of flooring shall have a Maximum weight of 70 kg. Holes in flooring (due to e.g. pipes passing through the flooring) and around plant vessels or other gaps shall be bonded with shop-welded toe plate. Minimum clearance around a pipe through the flooring will be provided using the greatest of the following hole-diameters: Diameter of hole is pipe diameter + insulation + 50mm Or Diameter of hole is flange diameter + 25m

3.7

Fabrication Tolerances

The structural components shall comply with the tolerance limits of relevant DIN NORMS, together with the following requirements and appendix 1.7

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

Crane girders: Negative camber shall not exceed


L 1000

Squareness of end plate and welded cleat connections The maximum deviation from squareness of the end shall be: - Plates and cleats with minimum dimensions less than or equal to 800 mm. - Plates and cleats with minimum dimension over 800 mm. 1 mm per 400 mm of depth to a maximum of 2 mm. 1 mm per 400 mm of depth to a maximum of 3 mm.

The maximum deviation from flatness across the plate or cleat in any direction shall be: Up to 800 mm Over 800 mm 2 mm 1 mm per 400 mm to a maximum of 3 mm

Edges of plates to be welded to other members: The flatness of plates at edges shall not deviateform straight or their specification configuration by more than 3 mm in any 3 meters. Twist in a member: The horizontal distance measured at the top flange from the vertical center line of the out of plumb web shall not exceed. For torsionally stiff member For flexible members
L 1500 L 1000

Where L is the length of the member Horizontal Camber in Flanges: The offsets, due to horizontal camber, measured halfway along the beam length and at each end, shall not exceed 6 mm.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

Flange width in mm 200

Or 3 mm, whichever is the lesser

All measurements shall be made with an approved steel tape or rule. Dimensions of all steelworks shown on the drawings or specified in standards shall be assumed to apply at 25 C.

3.8

HANDLING, SHIPPING, DELIVERY AND STORAGE

Delivery of steel shall be in the order needed for erection. The delivery sequence for the fabricated steel, unless otherwise noted, shall be as follows: loose base plates, steel embedded in concrete, erection bolts, first tier columns and framing for all its levels (including stairs and handrail), second tier columns and its framing etc. All the bolts, washers and nuts shall be packaged and delivered in rigid, weatherproof containers. Cardboard containers are not acceptable. Rail cars and/or trucks shall be loaded and cribbed so that others can readily unload them. Load in such a manner that continuous drainage will occur. All steel and its coatings shall be protected from damage caused by handling, storage or shipping. Adequate protection shall be provided for threads on sag rods, and any other threaded components so as to prevent damage during shipping and handling. Care shall be taken that holes and surfaces prepared for connection and the thread of bolts, anchors, mortises; etc. stay clean and undamaged. All materials designated for the care, custody and control of the Erector shall be received, unloaded, stored, and otherwise handled in a manner that will prevent distortion, deterioration or damage. The practice of throwing materials into piles on conveyances or from conveyances on to ground and of skidding steel members over each other shall not be permitted. The COMPANY reserves the right to reject all damaged or substandard material or documentation. All materials shall be stored well clear of the ground, on skids or timbers. These supports shall be spaced so that no damage results from deflection. Stacking of components more than three pieces high is not permitted. Steelwork components shall be handled and stored in such a manner as to minimise the risk of surface abrasion and damage. Fasteners and small fittings shall be stored in dry conditions. Steelwork shall be stored so that erection marks are clearly visible.

4.0 4.1

ERECTION General

Erection shall be in accordance with the drawings, contract documents and the AISC Specification for Structural Steel Buildings and the Code of Standard Practice for steel buildings and bridges.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

Fabricated structural steel shall be erected using methods and a sequence that will permit efficient and economical performance of erection, and that is consistent with the requirements in the contract documents. Loose timbers, metal sheeting, bolt buckets, tools, debris and temporary scaffolding shall be kept restrained or removed from the work areas. All equipment and materials shall be secured within the erectors care, custody and control, during the erection operation. The job site shall be maintained in a clean safe condition and all crating, waste materials and other refuse accumulated as a result of the erection activities shall be properly disposed of to approved dump. Where the steelwork erection is such that a crane required to transverse any permanent structure, the latter shall be adequately propped to prevent any other stressing. Drift pins shall be used only to align components ready for bolting .They shall not be used to enlarge misaligned holes 4.2 Temporary Supports of Structural Steel Frames

Based upon the information provided in drawing the erector shall determine, furnish and install all temporary supports, such as temporary guys, beams, false work, cribbing or other elements required for the erection operation. These temporary supports shall be sufficient to secure the bare structural steel framing or any portion there of against loads that are likely to be encountered during erection, including those due to wind and those that result from erection operations. The erector need not consider loads those that are unpredictable, such as loads due to hurricane, tornado, earthquake, explosion or collision. Temporary supports provided by the erector shall remain in place until the portion of the structural steel frame that they brace is complete and the lateral-load-resisting system and connecting diaphragm elements identified by the design drawings are installed

4.3

Setting Base Plates

Column base plates shall be set and shimmed to correct positions, elevations, and locations as shown on the design drawings. Anchor bolts shall be tightened only after grouting. Unless otherwise specified in the contract documents, anchor rods shall be set with their longitudinal axis perpendicular to the theoretical bearing surface.

4.4

Fit Up Connection

All matching holes for fastener shall register with each other so that fasteners can be inserted freely through the assembled members in a direction at right angles to the faces in contact. Drifting to align holes shall not distort the metal or enlarge the holes. Holes that cannot be aligned without enlargement shall be

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

reported to and remedial action agreed with the engineer of record. On bolted connections, the jointed parts shall be firmly drawn together. Where necessary, washers shall be tapered to give heads and nuts a satisfactory bearing. The length of each bolt shall be such that after tightening at least one tread projects through the nut and at least one full tread remains clear between the nut and unthreaded shank 4.5 Correction of Errors

The correction of minor misfits by moderate amounts of reaming, grinding, welding or cutting, and the drawing of elements into line with drift pins, shall be considered to be normal erection operations. Errors that cannot be corrected using the foregoing means, or that require major changes in member or connection configuration, shall be promptly reported to designer to enable the responsible entity to either correct the error or approve the most efficient and economical method of correction to be used by others. 4.6 Erection and shop Drawings

Erection drawings shall be prepared in accordance with the AISC documents listed in this specification. Erection drawings shall reference the corresponding design drawings. Every steel piece on the shop drawings shall reference the appropriate erection drawing. Erection and shop drawings shall be grouped in sets and identified separately for each structure or yard area. Erection drawings shall clearly show the mark number and position for each member. All fabricated steel sections shall be match-marked for field assembly with designating numbers or letters corresponding to the field erection drawings. Match marking of steel shall be done with suitable paint, waterproof ink or with pressed metal tags. In addition to the Fabricators identification marks, e ach item or bundle of walkways and platforms shall be marked with a unique tag number to clearly indicate its associated equipment. Each item or bundle of walkways and platforms shall also be indicated in the erection drawings. Shop drawings shall state the welding procedure to be used. Surface preparation and shop-applied coatings, including areas to be masked, shall be noted on the shop drawings. Bolt lists showing the number, grade, size and length of field bolts for each connection shall be supplied. These bolt lists may be shown on either the shop drawings or on separate sheets. In the event that drawing revisions are necessary, all changes showing the latest revisions shall be clearly flagged on the shop drawings. A shipping list (including total weight), bolts list, and a minimum of two sets of final erection and shop drawings shall accompany the first shipment of each release.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

4.7

Safety

A safety program shall address safety measures that the erector shall use during steel erection work. This program shall comply with the requirements of the contract documents, AISC Specification for Structural Steel Buildings and AISC Code of Standard Practice for Steel Building and Bridges and OSHA Standard 1926 Safety and Health Regulations for Construction. The erector shall provide floor coverings, handrails, walkways and other safety protection for the erectors personnel as required by law and the applicable safety regulations. Unless otherwise specified in the contract documents, the erector is permitted to remove such safety protection from areas where the erection operations are completed. For work at height the safety program shall recognize the requirements of OHSA Standard 1926 Subparts: 4.8 Assembly Lift Plan When necessary, particularly for pipe bridges over 20 m, assembly lift plan shall be issued by erector in order to demonstrate that proposed lift shall be performed safely and that assemblies being lifted shall remain free from distortion, undue bending and will maintain structural integrity, during the lift. Assembly lift plan shall contain detailed data on the extent of the lifted assembly, its weights, the structural calculations that prove structural stability of the assembled components during lifting operations, verification of the capacity capabilities for any cranes utilised in the lift, location and positioning of cranes, and a description of the rigging to be utilized

4.9

ERECTION TOLERANCES

Structural elements shall be considered plumb. Level and aligned in accordance with the AISC manual. The tolerances on position and alignment of member working points and working lines are as follows as per AISC Manual

4.9.1

Columns

Individual column shipping pieces are considered plumb if the deviation of the working line from a plumb line does not exceed 1:500, subject to the following limitations: a. The member working points of column shipping pieces adjacent to elevator shafts may be displaced no more than 25 mm from the established column line in the first 20 stories; above this level, the displacement may be increased 1mm for each additional story up to a maximum of 50mm. b. The member working points of exterior column shipping pieces may be displaced from the established column line no more than 25mm toward nor 50mm away from the building line in the first 20 stories; above the 20th story, the displacement may be increased 1.5mm for each additional story, but may not exceed a total displacement of 50mm toward nor 75 mm away from the building line.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

c. The member working points of exterior column shipping pieces at any splice level for multi-tier buildings and at the tops of columns for single tier buildings may not fall outside a horizontal envelope, parallel to the building line, 38mm wide for building up to 90m in length. The width of the envelope may be increased by 12mm for each additional 30m in length, but may not exceed 75mm. The member working points of exterior column shipping pieces may be displaced from the established column line, in a direction parallel to the building line, no more than 50mm in the first 20 stories; above the 20th story, the displacement may be increased 1.5mm for each additional story, but may not exceed a total displacement of 75mm parallel to the building line 4.9.2 Members Connecting to Columns

a. The horizontal alignment of members connecting to columns is considered acceptable if any error in alignment is caused solely by the variation in column alignment within permissible limits. b. The elevation of members connecting to columns is considered acceptable if the distance from the member working point to the upper milled splice line of the column does not deviate more than plus 5mm or minus 8mm from the distance specified on the drawings

4.9.3

Other Members

Members not covered above are considered plumb, level and aligned if the displacement of the individual member does not exceed 1:500 from a straight line struck between the support points of the member.

4.9.4

Adjustable Items

The alignment of lintels, wall supports, curb angles, mullions, and similar supporting members for the use of other trader, requiring limits closer than the foregoing tolerances, cannot be assured unless the CLIENTs plans call for adjustable connections of these members to the supporting structural frame. When adjustable connections are specified, the CLIENTs plans must provide for the total adjustment required to accommodate the tolerances on the steel frame for the proper alignment of these supports for other trades.The tolerances on position and alignment of such adjustable items are as follows: a. Adjustable items are considered to be properly located in their vertical position when their location is within 10mm of the location established from the upper milled splice line of the nearest column to the support location as specified on the drawings. b. Adjustable items are considered to be properly located in their horizontal position when their location is within 10mm of the proper location relative to the established finish line at any particular floor.

Sarcheshmeh Flash Smelting Furnace Project


Consultant: Document No. Contract No: 4074 DOCUMENT TITLE: 418/200-B00-T1-001 Rev. 01 Date: 26 July 2011

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Specification for fabrication and erection of steelwork

5.0 5.1 5.1.1

BOLTED PARTS REQUIREMENTS GENERAL Scope

This Specification covers the material workmanship and assembly of structural joints in structural steel connections using High Strength Bolts. Structural connections shall not be slip critical. All shear forces shall be carried out by bolts. One high strength bolt assembly shall consist of one heavy semi-finished hexagonal structural bolt, one heavy semi-finished hexagonal nut and two hardened washers. Hardened washers are required to provide adequate bearing area. Bolts with square heads and/or square nuts shall not be used. 5.2 MATERIAL High Strength Bolts are black bolts and shall confirm to ASTM A325 or ASTM A490. Designation or approved equivalent such as High strength Bolts Grade 8.8 or 10.9 respectively in accordance with ISO 898 (EN 20898-1:1991) Standard or DIN 7990. Nuts shall be hexagonal and confirm to ASTM A563, Grades DH or DH3 or equivalent to DIN 555. Washers shall be circular hardened washers confirming to ASTM F436 or DIN 7989.

5.3

BOLTED PARTS

All material within the grip of the bolt shall be steel. There shall be no compressible material such as gaskets or insulation within the grip. Bolted steel parts shall fit solidly together after the bolts are tightened and may be coated or uncoated. The slope of the surfaces of parts in contract with the bolt head or nut shall not exceed 1:20 with respect to a plane normal to the bolt axis. Using friction grip connections shall be based on CLIENTs written approval in detail design stage. The contact surfaces of the friction grip connections shall be left unpainted and to be noted on corresponding drawings.

5.4 5.4.1

BOLT HOLES General

All holes for bolts shall be punched or drilled except as noted herein. Material forming parts of a member composes of not more than five thickness of metal may be punched 1/16 inch (1.6mm) larger than the nominal diameter of the bolts whenever the thickness of the material is not greater than inch (19mm) for structural steel unless sub punching and reaming are required under sub-clause 2.4.6 hereinafter.

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When material is thicker than 20 mm for structural steel all holes shall either be sub drilled and reamed or drilled full size. Using flame or other method for reaming is strongly prohibited. Also when more than five thicknesses are joined or as required by sub-clause 2.4.6 hereinafter material shall be sub drilled and reamed or drilled full size while in assembly. When indicated on the drawings enlarged or slotted holes are allowed with High Strength Bolts.

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5.4.2

Punched Holes

The diameter of the die shall not exceed the diameter of the punch by more than 2.0mm if holes must be enlarged to admit the bolts. Such holes shall be reamed. Holes must be clean cut without torn or ragged edges. The slightly conical hole that naturally results from punching operations is considered acceptable 5.4.3 Reamed or Drilled Holes

Reamed or drilled holes shall be cylindrical, perpendicular to the member, and shall comply with the requirements of sub-clause 2-4-1 above as to size. Where practical, reamers shall be directed by mechanical means. Burrs on the outside surfaces shall be removed. Reaming and drilling shall be done with twist drills, twist reamers or rot broach cutters. Connecting parts requiring reamed or drilled holes shall be assembled and securely held while being reamed or drilled and shall is match marked before disassembling.

5.4.4

Accuracy of Holes

Holes not more than 1/32 inch (0.8mm) larger in diameter than the true decimal equivalent of the nominal diameter that may result from a drill or reamer of the nominal diameter are considered acceptable. The width of slotted holes, which are produced by flame cutting or a combination of drilling or punching and flame cutting 5.4.5 Accuracy of Hole Group

5.4.5.1 Accuracy Before Reaming All holes punched full size, sub punched, or sub drilled shall be so accurately punched that after assembling (before any reaming is done) a cylindrical pin 1/8 inch 93.2mm) smaller in diameter than the nominal size of the punched hole may be entered perpendicular to the face of member without drifting in at least 75 percent of the contiguous holes in the same plant. If the requirement is not fulfilled the badly punched pieces will be rejected. If any hole will not pass a pin 3/16-inch (4.8 mm) smaller in diameter than the nominal size of the punched hole this will be cause for rejection. 5.4.5.2 Accuracy After Reaming When holes are reamed or drilled at least 85 percent of the holes in any contiguous group shall after reaming or drilling show no offset greater than 1/32 inch (0.8 mm) between adjacent thicknesses of metal. All steel templates shall have hardened steel bushings in holes accurately dimensioned from the center lines of the connection as inscribed on the template. The centerlines shall be used in locating accurately the template from the milled or scribed ends of the members

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5.5 5.5.1

INSTALLATION General

Only as many fasteners as are anticipated to be installed and tightened during a work shift shall be taken from protected storage. Fasteners not used shall be returned to protected storage at the end of the shift. Fasteners shall not be cleaned of lubricant that is required to be present in as-delivered condition. Plain bolts must be oily to touch when delivered and installed. Lubricant shall be removed prior to painting. A tension-measuring device such as a Skidmore-Wilhelm Calibrator or any other acceptable bolt tensionmeasuring device shall be at job site when high strength fasteners are being installed and tightened. The tension-measuring device shall be used to perform the rotational capacity test and to confirm the following: The suitability to satisfy the requirements of Tables 5.5 A &5.5.B below, as applicable, of the complete fastener assembly, including lubrication if required to be used in the work (AISCSpecification for structural joints). The minimum bolt tensions as indicated in tables above equal to 70% of specified minimum tensile strength of bolts in accordance with ASTM Specifications for tests of full-size A 325 and A 490 bolts loaded in axial tension. The calibration of wrenches, if applicable.

TABLE 5.5- A Required Fastener Tension

Bolt Size (mm) M 16 M 18 M 20 M 22 M 24 M27 M 30 M 36

A325 (Grade 8.8)KN 88 111 142 176 205 267 326 475

A490 (Grade 10.9)KN 114 140 170 210 250 315 390 560

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TABLE 5.5-B Required Fastener Torque

Bolt Size (mm)

A325 (Grade 8.8) Spanner (mm) Kg.m 0.08 24 30 32 36 41 45 55 0.2 0.36 0.52 0.64 1 1.28 2.24 N.m 0.16 0.28 0.48 0.72 0.88 1.32 1.76 3.04

A409 (Grade 10.9) Grease Oil coated coated (KN.m) (KN.m) 0.1 0.25 0.45 0.65 0.8 1.25 1.65 2.8 0.21 0.35 0.6 0.9 1.1 1.65 2.2. 3.8

M12 M16 M20 M22 M24 M27 M30 M36

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TABLE 5.5-C Nut Rotation from the Snug-Tight Condition Deposition of Outer Face of Bolted Parts

One face normal to bolt axis Bolt length (under side Both faces Both faces normal to bolt axis and other sloped not more of head to end of bolt) normal to bolt and other sloped not more than than 1:20 (beveled washer not axis 1:20 (beveled washer not used) used)

Up to & including 4xD* 1/3 turn

1/2 turn

2/3 turn

Over 4xD but not exceeding 8xD*

1/2 turn

2/3 turn

5/6 turn

Over 8xD but not exceeding 12xD*

2/3 turn

5/6 turn

1 turn

*: D is nominal bolts diameter In the above table the nut rotation is relative to the bolt regardless of the element (nut or bolt) being turned. For bolts installed by turn and less, the tolerance should be plus or minus 30 degrees; for bolts installed by 2/3 turn the tolerance should be plus or minus 45 degrees. Bolts shall be installed in all holes of the connection and brought to a snug tight condition. Snug tight is defined as the tightness that exists when the plies of the joint are in firm contact. Snug tightening shall progress systematically from the most rigid part of the connection to the free edges. The bolts of the connection shall then be retightened in a similar systematic manner as necessary until all bolts are simultaneously snug tight and the connection if fully compacted

5.5.2

Requirements for Washers

Washers shall be circular hardened washers conforming to ASTM F-436 or approved equivalent. Where the outer of the bolted parts has a slope greater than 1:25 with respect to a plane normal to the bolt axis, a hardened beveled washer shall be used to compensate for the lack of parallelism. Irrespective of the tightening method, hardened washers shall be used under both head and nut of all bolts

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5.5.3

Turn-of NUT Tightening

Verification testing using a representative sample of not less than three bolt and nut assemblies of each diameter, length and grade to be used in the work shall be performed at the start of work in a device capable of indicating bolt tension. This verification test shall demonstrate that the method for estimating the snug tight condition and controlling the turns from snug tight to be use by the bolting crew develops a tension not less than 5 percent greater than the tension required by Tables 5.5-A or 5.5-B above, as applicable. Periodic retesting shall be performed when ordered by the CLIENT. After snug tightening fasteners and fully compacting the connection, all bolts in the connection shall be tightened further by the applicable amount of rotation specified in Table 5.5-C above. During the tightening operation there shall be no rotation of the part not turned by the wrench. Tightening shall progress systematically from the most rigid part of the joint to its free edges

5.5.4

Calibrated Wrench Tightening

Calibrated wrench tightening may be used only when installation procedures are calibrated on a daily basis and when a hardened washer is used under the element turned in tightening. Standard torques determines from tables or from formulas, which are assumed to relate torque to tension, is not acceptable. When calibrated wrenches are used for installation, they shall be set to provide a tension not less than 5 percent in excess of the minimum tension specified in Tables 5.5-A or 5.5-B above, as applicable. The installation procedures shall be calibrated by verification testing at least once each working day for each bolt diameter, length and grade using fastener assemblies that are being installed in the work. This verification testing shall be accomplished in a device capable of indicating actual bolt tension by tightening three typical bolts of each diameter, length and grade from the bolts being installed and with a hardened washer from the washers being used in the work under the element turned in tightening. Wrenches shall be recalibrated when significant difference is noted in the surface condition of the bolts, threads, nuts or washers. It shall be verified during actual installation in the assembled steelwork that the wrench adjustment selected by the calibration does not produce a nut or bolt head rotation from snug tight greater than that permitted in Table 5.5-C above. If manual torque wrenches are used, nuts shall be turned in the tightening direction when torque is measured. When calibrated wrenches are used to install tension bolts in a connection, bolts shall be installed with hardened washers under the element turned in tightening bolts in all holes of the connection and brought to a snug tight condition. Following this initial tightening operation, the connection shall be tightened using the calibrated wrench. Tightening shall progress systematically from the most rigid part of the joint to its free edges. The wrench shall be returned to touch-up previously tightened bolts, which may have been relaxed as a tightened to the prescribed amount

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5.5.5

Direct Tension Indicator Tightening

When Direct Tension Indicators (DTIs) are to be installed with high-strength bolts to indicate bolt tension, they shall be subjected to verification testing described below and installed in accordance with the method specified below. Unless otherwise approved by the CLIENT, the DTIs shall be installed under the head of the bolt and the nut turned to tighten the fastener. The manufacturers recommendations shall be followed for the proper orientation of DTI and additional washers, if any, required for the correct use of the DTI

5.5.5.1 Verification Verification testing shall be performed in a calibrated bolt tension-measuring device. A special flat insert shall be used in place of the normal bolt head holding insert. Three verification tests are required for each combination of fastener rotational-capacity lot. DTI lot and DTI position relative to the turned element (bolt head or nut) to be used on the project. Turning the element not against the DTI shall be prevented from rotating shall tighten the fastener. The purpose of the verification testing is to ensure that the fastener will be at or above the desired installation tension when half or more of the spaces in the DTI have a gap less than 0.005 inch (0.13 mm) and that the fastener will not undergo excessive plastic deformation at the minimum gap allowed on the project. The verification tests shall be conducted in two stages. The bolt, nut and DTI assembly shall be installed in a manner so that at least three and preferably not more than five threads are located between the bearing face of the nut and the bolt head. The fastener shall be tightened first to the load equal to those listed in Tables 7.6.6-1-D or 7.6.6.1-E below, as applicable, under Verification Tension for the grade and diameter of the fastener. If an impact wrench is used, it is acceptable to tighten to a load slightly below the required load and subsequently a manual wrench used to attain the required tension. The number of refusals of a 0.005 inch (0.13mm) tapered feeler gage in the spaces between the protrusions shall be determined and recorded. The number of spaces is listed in Tables 5.5.5-D or 5.5.5-E, as applicable. The number of refusals shall not exceed the number listed under Maximum.

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TABLE 5.5.5-D AISC-Specification for structural joints

Bolt Dia. (in)

Verification Tension (kips) A325 A490 25 37 51 67

Maximum VerificationRefusal s A325 1 2 2 2 A490 2 2 2 3

DTI Spaces

Minimum Installation Refuel A325 2 3 3 3 A490 3 3 3 4

A325 4 5 5 6

A490 5 6 6 7

5/8 3/4 7/8 1

20 29 41 54

TABLE 5.5.5-E DIN Norm, Specification for structural joints

Verification Tension Bolt Dia. (mm) (K. Newton) Grd. 8.8 M16 M18 M20 M22 M24 92 117 144 174 207 Grd. 10.9 115 146 180 218 259

Maximum Verification Refusal Grd. 8.8 1 2 2 2 2 Grd. 10.9 2 2 2 2 3

DTI Spaces

Minimum Installation Refuel Grd. 8.8 2 3 3 3 3 Grd. 10.9 3 3 3 3 4

Grd. 8.8 4 5 5 5 6

Grd. 10.9 5 6 6 6 7

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Verification Refusals in Tables 5.5.5-D or 5.5.5-E, as applicable, for the grade and diameter of bolts for uncoated DTIs. The DTI lot is rejected if the number of refusals exceeds the values in the tables. After the number of refusals is recorded at the verification load, the fastener shall be further tightened until the 0.005 inch (0.13mm) feeler gage is refused at all spaces and a visible gap exists in at least one space. The load, at this condition, shall be recorded and the tension-measuring device removed from the fastener. The nut must be able to be reassembled by hand for the complete thread length of the bolt excluding thread run out. If the nut cannot be assembled for this thread, the DTI lot is rejected unless the load recorded is less than 95 percent of the average load measured in the rotational capacity test for the fastener lot as specified in clause 7.6.2 part (7) above. If the bolt is too short to be tested in the calibration device, the DTI shall be tested on a long bolt in a calibrator to determine the number of refusals at the Verification Tension listed in tables7.6.6.1-D or 7.6.6.1-E, as applicable. The number of refusals shall not exceed the values listed under Maximum Verification Refusals in tables' 5.5.5-D or 5.5.5-E, as applicable. Another DTI from the same lot shall then be tested with the short bolt in a convenient hole in the work. The fastener assembly shall be tightened until the 0.005-inch (0.13 mm) feeler gage is refused in all spaces and a visible gap exists in at least one space. The fastener shall then be disassembled by hand for the complete thread length of the bolt excluding thread run out. The DTI lot will be rejected if the nut cannot be assembled for this thread length. 5.5.5.2 Installation Installation of fasteners using DTIs shall be performed in two stages. The fastener element against the DTI shall be held against rotation during each stage of the installation. The connection shall be first snagged with bolts installed in all the holes of the connection and initially tightened sufficiently to bring all the plies of the connection into firm contact. The number of spaces in which 0.005-inch (0.13 mm) feeler gage is refused in the DTI after snagging shall not exceed those listed under Maximum Verification Refusals in Tables 5.5.5-D or 5.5.5-E, as applicable. If the number exceeds the values in the applicable table, the fastener must be removed and another DTI installed followed by re-snagging of the fastener. The connection shall be further tightened unit the number of refusals of the 0.005 inch (0.13mm) feeler gage is equal to or greater than the number listed under Minimum Installation Refusals in Tables 5.5.5-D or 5.5.5-E, as applicable, if the fastener is tightened so that no visible gap in any space remains, the bolt and DTI shall be removed and replaced by a new properly tightened fastener and DTI.

6.0 6.1 6.1.1

WELDING PROCEDURE & REQUIREMENTS GENERAL Scope

This Specification covers the welding requirements of all structural steelwork.

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6.1.2

Application

This Specification is applicable to the following works for the welding of structural steelwork: Preparation of shop and as-built drawings. Shop or field fabrication of plate girders, braced girders and trusses, built up

6.2

WELDING PROCEDURE SPECIFICATION (WPS)

A welding procedure is defined as the method and sequences to be adopted to achieve a satisfactory welded joint when carried-out by competent workmen under the expected conditions of fabrication. Prior to the commencement of welding works for any fabrication the CONSTRUCTION CONTRACTOR shall submit to the CLIENT all Welding Procedure Specifications (WPS) together with relevant Welding Procedure Qualification Records (PQR) for approval. Only WPS with relevant PQR approved by the CLIENT shall be used. The WPS submitted to the CLIENT for approval shall include welding details including all of the essential and non-essential variables for each process used, and appropriate test results in accordance with AWS D1-1. The WPS shall also make reference to AWS D1-1 and ASTM, indicating the size and thickness range as applicable. Construction Contractors standard forms shall be approved by client before commencement of fabrication job.

6.3

WELDING PROCEDURE QUALIFICATION TEST (WPQT)

All welding procedures shall be qualified with the requirements of AWS D1-1 and ASTM. For welds requiring post-weld heat treatment, hardness tests shall be conducted on completion of heat treatment. All Welding Procedure Qualification Tests shall be carried-out in the presence of and certified by the AUTHORIZED REPRESENTATIVE OF CLIENT and on Official Authority selected or approved by the AUTHORIZED REPRESENTATIVE OF CLIENT. The Fabrication CONTRACTOR for the above-mentioned presence and certification shall give sufficient advance notice. The AUTHORIZED REPRESENTATIVE OF CLIENT reserves the right to make or decides on any other arrangement. 6.4 WELDING ELECTRODES AND CONSUMABLES

The deposit analysis of welding consumables shall match with base material unless specifically approved by the CONTRACTOR otherwise, in writing.

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Actual weld deposit analysis and weld metal physical properties are required for all alloy welding. The information shall be taken from procedure qualification and/or relevant testing. Data listed in consumable manufacturers catalogue will not be acceptable. Mill test certificates of welding consumables will be required for each batch, lot or heat. As a minimum requirement all welding consumables shall be stored and/or dried in accordance with the Manufactures recommendations. The flux/wire combination to be used in fabrication shall be the same as used in the procedure qualification. Changes in brand name or grade of flux will require new qualification. Electrodes shall be generally in accordance with AWS A5.1, E70, xx for structural elements and pipe supports pipes with steel grade of ST-52 or equivalentST-37. E60, xx electrode can be used in fabrication of secondary elements such as pipe supports or platforms. with steel grade lower than ST-37 or equivalent. Only base metals and filler metals listed in AWS D1.1 section 3, table 3.1 may be used in pre-qualified..

6.5

PREPARATIONS FOR WELDING

All preparations for welding shall be in accordance with AWS D1-1. The SITE ENGINEER should have approved shop drawings, which would have been prepared by Fabrication CONTRACTOR. The fabricator and EPC contractor is responsible for all the fabrication drawings and only connections standard drawings will be approved by client

6.5.1

Welding Program

A Welding Program shall be prepared by the fabrication CONTRACTOR both for working in workshop and on the field. The SITE ENGINEER, before the commencement of the works, shall approve the programs For the purpose of Preparations for Welding the Welding Program shall include the following: Schedule agreement between Welding Procedure Specification (WPS) Welding Procedure Specification (WPS). Welding Procedure Qualification Test (WPQT). Welders Qualification Records. Shop Drawings, prepared by the Fabrication CONTRACTOR as and if required, showing the details of the welded connections.

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6.5.2

Verifications Before Welding Works

The following verifications will be required before the start of welding works. Surfaces to be welded shall be controlled to be clean and dry. Welding operation shall not be carried-out during bad weather exposure. Ambient temperature shall not be less than 5 degrees centigrade The surface temperature of steel parts shall not be less than zero degrees centigrade. Welding operators equipments shall be in a good working condition.

Earthing connections shall have been installed correctly

6.5.3

Preparation for Chamfering

The operator shall choose the shape of chamfering according to the Welding Procedure Specification (WPS) and connection or joint details of Shop Drawings. Transition of width at butt joints of parts having unequal widths shall have slopes in accordance with AWS that recommends . Stains of paint, oil, rust, etc. shall be eliminated prior to welding. Steel and weld metal may be thermally cut providing a smooth and regular surface free from cracks and notches in produced. An accurate profile may be secured by the use of mechanical guide. Grinding shall be used to smoothen the surfaces, if the SITE ENGINEER deems it necessary. Freehand thermal cutting shall not be permitted except by the previous written approval of the SITE ENGINEER

6.5.4

Surface Conditions

Surfaces shall be dry, clean and free from paint, oil, rust and other stains and debris that can affect the quality of connections, joints, welds, and/or welding operations

6.5.5

Pre-Heating

Pre-Heating temperature shall be established in relation with the design code minimum thickness, carbon equivalence, welding heat input, and severity of restraint. Pre-Heating temperature shall be specified in the Welding Procedure Specification (WPS).

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6.5.6

Inter-pass-Temperature

The maximum inter-pass temperature for all materials shall be specified in the Welding Procedure Specification (WPS) prepared by the Fabrication CONTRACTOR and approved by the SITE ENGINEER. The temperature shall be correctly checked during the works. 6.6 EXECUTION OF WELDING WORKS

Before commencing the work PIM should be held on. For the execution of the Welding Works the Welding Program, prepared by the CONSTRUCTION CONTRACTOR and approved by the SITE ENGINEER before the commencement of the works shall include the following: For each type of connection and joint: a. Method of welding. b. Preparation of the elements to be welded. c. Positioning of the elements to provide for welding space at the bottom of the chamfer, pointing at the weld or attachment by clamps. d. Order of execution. Each type of connection and joint must be characterized by the grade and the quality of the steel, the thickness of the members to be assembled and the respective position of the members for butt welding, fillet welding, lap welding, etc. For each fillet weld: a. b. c. d. e. f. g. Dimension of the fillet weld. Trade name and diameter of the electrode. Electric current supply. Welding position. Starting point of each pass and feed direction. Precautions taken to avoid or eliminate end craters.

All welds shall be obligatorily executed according to the Construction Drawings, Shop drawings, and the Welding Program. Also all slag shall be removed from finished welds prior to sand blasting. 6.7 INSPECTION AND TESTING

The COMPANY reserves the right to inspect the materials and fabrication at any time to assure that the materials and workmanship are in accordance with this specification and applicable codes. Inspection of welding shall be performed in accordance with the Structural Welding Code, AWS D1.1. or INBC 10 table 10.4.1

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A program for inspection and non destructive testing of welds shall be submitted to the COMPANY for approval before the start of the welding operation. The minimum NDT levels will be as follows, All welds shall be 100% visually inspected the acceptance criteria shall be in accordance with AWS D1.1 Table 6.1. or INBC 10 table 10.4.1. All main beam splices shall be additionally subjected to 100% radiography or ultrasonic inspection and all other major load bearing welds shall be subjected to 10% magnetic particle inspection. Alternatively 10% RT of butt welds greater than 75 cm2. Acceptance criteria for radiographic, ultrasonic and magnetic particle inspection shall be in accordance with AWS D1.1. Certified mill test reports for each heat of structural steel and each lot of high-strength bolts shall be available for review by the COMPANY. All materials shall be inspected immediately after receipt on site in order to ensure that the materials are not damaged, to verify that all the items on the packing list have been supplied and to ensure that all documentation has been received. Shop inspection shall include, but not be limited to, the following:

7.0 7.1

Field Painting Standard

Field painting shall be in accordance with Engineering Specification for Painting 418/200-D00-P1-004, or Iranian National code part 10. 7.2 Damaged Areas

Immediately after erection, all surfaces on which the shop coating has been damaged shall be thoroughly cleaned and touched up with the same coating and in accordance with painting standard. 7.3 Field Inspection CLIENTs representative shall have the right to inspect the structural steel at any time, to assure that the materials and workmanship are in accordance with this standard and contract.

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Appendix 1. Fabrication Tolerances

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Table 1-1

Fabrication Tolerances (According to AISC 303)

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Table 1-1

Fabrication Tolerances (contd.)

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Table 1-1

Fabrication Tolerances (contd.)