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OMRON HEALTHCARE VIETNAM FACTORY PROJECT

CONSTRUCTION METHOD AND


QUALITY CONTROL PLANNING
For

STEEL STRUCTURE WORK

OBAYASHI VIETNAM CORPORATION


BINH DUONG – VSIP II SITE OFFICE
2007

Project Manager Site Manager Building Engineer


CONTENTS

1- GENERAL
1.1 Scope
1.2 Alteration

2- OUTLINE OF PROJECT
2.1 General parameters
2.2 Steel structure parameters

3- MATERIAL SPECIFICATION

4-SITE PREPARATION

5- METHOD OF ERECTION

6- QUALITY CONTROL
6.1 Members
6.2 Connection
6.3 Alignment
6.4 Adjustment of bracing
6.5 Roofing and wall cladding
6.6 Final inspection

7-STEEL COLUMN BASE TREATMENT

8- MEASUREMENT OF SAFETY

9-SCHEDULE

10-DOCUMENT ATTACHMENT
 10.1 Erection schedule
10.2 Erection method drawings
10.3 List of Tools and Equipment
10.4 Working Procedure for MAXSEAM Panels
10.5 Inspection and Control Form
10.6 Grouting mortar catalog
1- GENERAL

1.1 Scope
This Construction Method and Quality Control Planning shall be applied to steel
structure erection work. Based on the design and specification, this document
provides a proper procedure and management of the structure erection work.

1.2 Alteration
This Construction Method and Quality Control Planning may be subject to change or
alter due to its revision. In that case, corrected or adjusted requirements shall prevail
after its official written approval.

2- OUTLINE OF PROJECT
2.1-General parameters:

* Name of the project: OMRON HEALTHCARE VIETNAM FACTORY

* Location: 28 Road No. 2, VSIP II, Ben Cat Dist., Binh Duong
Province.

* Client: OMRON HEALTHCARE MANUFACTURING VIETNAM Co., Ltd

* Design: OBAYASHI VIETNAM CORPORATION

* Contractor: OBAYASHI VIETNAM CORPORATION

* Construction period: June 08th 2007 to November 23rd 2007

* Land area: 38,369.1 m2

* Building area: 6,538.57 m2

2.2-Steel structure parameters:

• Factory main structure:


• Office main structure:
3- MATERIAL SPECIFICATION

No. Components Specifications Minimum Strength

Plates≦6mm
ASTM A570 Grade 50 Type 1 Fy = 34.5 kN/cm2
thick
1 Built-up
Plates>6mm
ASTM A572 Grade 50 Type 1 Fy = 34.5 kN/cm2
thick
Tubes JIS-G3466 Grade 50 Type 1 Fy = 32.5 kN/cm2

Channels EN-10025 S355JR Fy = 35.5 kN/cm2


2 Hot Rolled
Channels JIS-G3101-SS400 Fy = 24.5 kN/cm2

Beams JIS-G3101-SS400 Fy = 24.5 kN/cm2

Painted ASTM A607 Grade Fy = 34.5 kN/cm2


Cold
3 Pre-
Formed ASTM A653 SS50 Class 1 G90 Fy = 34.5 kN/cm2
Galvanized
ASTM A792 Grade 50B: Coating
4 Exterior Wall & Roof Panel Fy = 34.5 kN/cm2
AZ150
5 Mezzanine Deck Panel ASTM A653 SS50 Class 1 Coating G60 Fy = 34.0 kN/cm2
ASTM A792 Grade 50B: Coating
6 Interior Liner Panel Fy = 34.5 kN/cm2
AZ150
Rods TCVN-1765-75 CT38 or higher grade Fy = 37.2 kN/cm2
7 X-Bracing
Angles TCVN-1765-75 CT38 or higher grade Fy = 37.2 kN/cm2

8 Anchor Bolts TCVN-1765-75 CT38 or higher grade Fy = 37.2 kN/cm2


2
ASTM A325 M Type 1 Hot D Ft = 30.3 kN/cm
9 High Strength Bolts
Galvanized Fu = 72 to 83 kN/cm2

Ft = 13.3 kN/cm2
10 Machine Bolts DIN 933 Class 4.6/4.8 Yellow Chromate
Fu = 40.0 kN/cm2
4. SITE PREPARATION

Stock yard must be prepared before unloading of steel structure materials.


(see attached layout plan)
All steel structure materials are carefully checked and loaded to ensure safe delivery and
to avoid shortages. Materials are packaged and can be unloaded by use of heavy duty
Fork-lift or by crane.

At the time of unloading, materials should be checked by both Obayashi engineer and Zamil
engineer responsible with the Bill of Materials or Packing List. Any shortages must be reported to
Zamil Steel immediately by official letter.
Materials should be laid out in order. The layout will depend on size of building and site
conditions. Use timber blocks between bundles or members for ease of handling.

5. METHOD OF ERECTION

Phase 1: ANCHOR BOLT SETTING


Step 1: Marking for boundary line of starting column on footing
Step 2: Check and adjust position of starting column-rebar if necessary.
Step 3: Set form for starting column and support them carefully.
Step 4: Marking for bolt-group-center line on side of form.
Step 5: Set template with anchor bolts. The template position is higher than concrete
surface level. Marking line of bolt-group-center and each bolt must be matched on
the template. Adjust position of the template according to marking line on footing
by plum bob.
Step 6: Welding diagonal supporting bar to column rebar and anchor bolt.
Step 7: Check position of anchor bolt again.
Step 8: Protect bolts head by masking tape
Step 9: Cast concrete for starting column
Step10: After casting concrete, re-check anchor bolt position. Adjusting the template if
necessary.
Phase 2: STRUCTURE ERECTION

Step 1:
• Set up 2 side columns of braced bay (between Grid 4 and Grid 5), including
bracing beams.
• Erect interior columns (along grid C1-4 and C1-5) with temporary bracing.
• Tighten anchor bolts and nuts sufficiently to prevent columns from rocking.
• Assemble rafter components of Grid 4 on the ground into connection.
• Install all bolts in rafter splices to proper tension, using turn-off- nut method
and torque wrench.
• Raise the first assembled rafter on top of column by cranes.
• Install bolts of rafter through column connection and tighten to snug
position.
• Secure all temporary, wire ropes bracings, plumb and align the column and
rafter before releasing the crane.

Step 2:
• Using same procedure to assemble other parts of the rafter of Grid 5 (A – F).
• Place it on top of interior columns.
• Bolt to column connections and tighten.
• Secure temporary bracings.

Step 3:
• Assemble the rafter of Grid 6 (same as the first erected rafters). Connect and
bolted to column splices. The crane has to keep holding the rafter in position
until sufficient purlins ( 1/3 of total purlins at that area ) have installed to
provide rigid support for the bay. The crane can release if having temporary
bracing cables for both sides at interval of maximum 10 m.
• Continue erecting the next rafters of the brace bay.
• Completing purlins, flange braces, roof bracings.
• Plumb and align before proceeding to erect the next bays.
• After checking the alignment and square-ness, tighten again anchor bolts,
column connection, girts bolts, and eave strut bolts to required tension by
torque wrench.

Step 4:
• Continue erecting columns rafters for the next bays, using same procedure
described in Step 1.
• Complete installation of purlins and girts.
• Complete roof angle bracings, and all secondary members.

Step 5:
• Fabrication and installation of MAXSEAM roofing panels. (See attached
“Erection Procedure for Maxseam roof Panel”)

Step 6:
• Install wall panels, downspouts and gutters.
• Complete trims and accessories.

6. QUALITY CONTROL

- Inspection is necessary at all steps of erection process, from the times materials are
first received until the structure is completely installed.

- Inspection during the erection process shall be continuous in order to prevent the
occurrence of possible damage and to require the maintenance of high standard
workmanship. Inspection shall include members, painting, connection, alignment,
bracings, roofing and wall cladding, equipment and false work.

6.1. Members
- Inspection members for damage due to mishandling or careless storage.

- Make sure that each member is placed in its proper position in the structure and that
fillers, shims, and washers required for the type of connection are properly used.

- Prevent abuse of material by bending, straining, or heavy pounding by sledges.

- Inspect the accuracy of match-marked connections.

- Check the painting work.

- After finishing the painting work, all steel members shall be checked to make sure
that small area of steel members is painted.

6.2. Connection

a/ Anchor bolts:
- Check the tolerance of dimensions between anchor bolts to meet the required
tolerance (5mm).

- Check the tightness of anchor bolts to meet the require forces.

b/ Bolts connection:
- The supervisor has to assure himself that the wrenches used are calibrated properly
so that bolts are tightened the proper amount. Also the proper lengths of bolts shall
be checked.

- After connecting, all bolts shall be tightened to obtain the required tension values
• Using turn-off nut method: Tighten more120o+/-30o for bolt diameter
>12mm, tighten more 60o-0+30o for bolt diameter = 12mm.
• Torque wrench: the actual value must be within the recommended value +/-
5_10%.

- Every connection point shall be inspected with the inspection record that is made by the
team leader, with the confirmation of Obayashi responsible engineers and Site Manager.
The actual value of tension or torque moment of every bolt in the connection shall be shown
on the record.

Bolt Tension Required (Table 1)


Bolt diameter Min- tension Recommended Torque

D N M
mm KN N.m
12.7 53 136
15.9 84 271
19.0 125 481
22.2 173 773
25.4 226 1153
28.6 249 1437
31.7 317 2027
35.0 378 2658
38.1 459 3526

6.3. Alignment
- After the first bay (braced bay) is erected, the columns shall be made plumb and the
rafters shall be straight.

- After completing the erection of main frames the alignment check shall be done
again, before continuing the erection of the successive bays.

The tolerance of column plumb must be within the value of 1/500 of column height,
but can not be more than25mm.

The tolerance of Rafter alignment (from straight rafter - line) must be within the value
of 1/300 of Span.

-After completing the erection of main frames, the final check of alignment (plumbing and
straightness) for the all columns and rafters of whole building shall be done.

6.4. Adjustment of bracing

- Adjustable diagonal bracing is fixed after all parts of the structure are in place.

- In bolted structures having diagonal bracing, wall bracings are adjusted after the columns
are plumbed, and roof bracing are adjusted when rafters are in straight line.

6.5. Roofing and Wall cladding

Check sequence of roof panels on roof.


Check correct starting- end position of roof and wall panels.
Check right screws using.
All screws must be perpendicular to panels, and rubber washer thickness must be
from 1.00 to 1.20mm.
(See attached “Erection Procedure for Maxseam roof Panel”)

6.6. Final Inspection


After completing all trims and accessories, a final inspection of the building shall be
done:

All bracings in position and tightened.


All bolts in place and high strength bolts tightened to correct tension value.
Check that roof and gutters are clear of debris and ferrous metals.
Check improper drilled screws.
Check opening for joinery.
Touch up any damaged paint.

7. STEEL COLUMN BASE TREATMENT


Procedure
a. Cleaning of concrete column top surface.

b. Marking centerline of steel column.

c. Leveling mortar base (using high grade mortar G150 ) at middle of 4 anchor-bolts
with the same level of bottom of column-base-plate.

d. Checking level of column.

e. Grouting mortar for column base. (Sika- grout 212-11: see attached catalog)
8. MEASUREMENT OF SAFETY

●Each workers shall be physically qualified to perform the duties to which he is assigned.
●Workers shall always wear hard helmets, shoes, uniforms and gloves.
● Workers shall wear safety belts.
●Goggles, face masks shields or helmets are required for scaling, grinding, cutting, and
welding operations.
●Maintenance of machines used in the erection work shall be done properly.
●Setting of safety rope on Roof when carry out the roofing work.
●Setting of signboard, and barricade by ropes around working area, do not permit any
person without duty to enter the working area.
●The crane condition (including machine parts, wire rope) must be checked everyday.
●Safety meeting shall be done everyday before starting work.
●Scaffoldings shall be arranged properly.
●Daily cleaning shall be done everyday.

9. SCHEDULE

10. DOCUMENTATION ATTATCHED


LIST OF BASIC ERECTION EQUIPMENTS
The following items are basic equipments for erecting xxx project.

LIFTING EQIPMENT, ROPES AND LINES.

1. 01 No. of 45 MT Crane
2. 01 No. of 20 MT Crane
3. 04 Nos. of 12 MT Crane
4. Assorted Slings in various size and Length.
5. Steel guy lines for temporary bracing.
6. Manila Ropers for hand lines.

ELECTRICAL EQIPMENTS

1. Welder Machine
2. Extension Leads and pigtails.
3. Heavy Duty Drill ½”.
4. Heavy Duty Drill ¼”.
5. Heavy Duty Screw gun w/Hex Sockets.
6. Electric Nibbler.
7. Electric Shear.
8. Angle Grinder.
9. Concrete Drill.

HAND TOOLS.

1. Socket Wrench ¾” or 1” drive with asst. Sockets.


2. Open ended wrenches assorted imperial size.
3. Spud wrenches 15/16” opening up to 1-1/8”
4. Crescent wrench – ½”.
5. Pipe wrench.
6. Screw drivers Standard and Philips.
7. Aviation snip – Left and right.
8. Vice grips.
9. Pop rivit puller
10. 4bl Sedge hammer.
11. Hacksaw frame and blades.
12. Wood saw.
13. Spirit level and plumb – bob.
14. Chalk line.
15. Steel measuring tapes 30m and 8m.
16. Utility knife.
17. Staple applicator.
18. Oxy-Acetylene cutting outfit.
19. Welding hood.
20. Hard hats.
21.Safety belts – Bolt bags.
22. Broom.
23. Masonry drill bits 12mm.
24. Extension ladders.
25. Step Ladders.
26. Scaffolding System.
27.Hilti gun, cartridges and nails
TOOLS AND TACKLES
No. Item Unit Q'ty Part Number/Made in
Machinery      
1 Portable Rollformer Set 1 # 38624
2 Portable Air Compressor Pcs 1 # 051394
3 Seamer Pcs 2 567B604050005
4 Electric Hydr 1 alic Engine Unit Pcs 1 86541
5 Diesel Engine Unit Pcs 1 405DAC38/12H
6 Uncoiler Pcs 2 USA
7 Crimper Pcs 2 USA
Tools      
1 Combination Wrench Set 2 Stanley
2 Allen key Set Set 2 Kingtony
3 Strap Wrench 18" Pc 1 Stanley
4 Screw Driver Pcs 8 Goodman
5 Adjustable Wrench 24" Pc 1 USA
6 Wrench Pcs 2 Stanley
7 Sweeping Broom Pcs 3 Vietnam
8 Stapler for insulation Pcs 15  
9 Mastic Gun (Silicon) Pcs 8 China
10 Goggles Pcs 45  
11 Fire Extinguisher Pcs 2  
12 Nibbler Pcs 1 Makita
13 Cutting Snip 10" Pcs 6 Stanley
14 Hack Saw Pcs 3 Italy
15 C Clamps various size Pcs 4 Vietnam
16 Electricextension 50M Pcs 4 Vietnam
17 Screw Gun Pcs 21 Makita
18 Drill machine Pcs 1 Makita
19 Grinder (small) Pcs 1 Makita
20 Nylon Rope Mett 750 Vietnam
21 Riveter (heavy duty) Pcs 2 Stanley
22 Venier Caliper (digital) Pcs 1 Mitutoyo
23 Vice Grip 8" Pcs 8 Stanley
24 Utility Knife Pcs 12 Stanley
25 Line Man's Pliers 8" Pcs 2 Stanley
26 Long Nose Pliers 6" Pcs 2 Stanley
27 Side Cutter 8" Pcs 6 Stanley
28 Digital tester (VOM) Pcs 1 Koritsu
29 First Aid Kit Set 1 Vietnam
30 Plastic tarpaulin cover 8mx10m Pcs 4 Vietnam
31 Plastic Galoon 20 litter Can 4 Vietnam
32 Feller Gauge mm Set 1 China
33 3 Claw Mechanical Puller small Pcs 1 Japan
34 Hydraulic Jack 20 tons Pcs 1 Japan
35 Level Pcs 1 Stanley
36 Scow Bar 1m length Pcs 1 Vietnam
37 Electric soildering Iron 100 watts Pcs 1 Czech
38 Oiler Pcs 1 India
39 Ball Pien Hammer (medium) Pcs 1 Stanley
40 Torch Pcs 1 Vietnam
41 Tape 8 meters Pcs 2 Stanley
42 Tape 30 meters Pcs 2 Stanley
43 Tape 5 meters Pcs 5 Stanley

TOOLS AND TACKLES

No. Item Unit Q'ty Part Number/Made in


Support      
1 Scaffolding 1.5 meters Pcs 40 Hung Cuong Co.Ltd
2 Bracing for scaffolding Pcs 40 Hung Cuong Co.Ltd
3 Platform for scaffolding Pcs 20 Hung Cuong Co.Ltd
4 Jack for scaffolding Pcs 12 Hung Cuong Co.Ltd
5 Wheel for scaffolding Pcs 12 Hung Cuong Co.Ltd
6 Spreader bar Pcs 2 ZSV
7 Stair for scaffolding Pcs 40 Hung Cuong Co.Ltd
8 Extension Cord (Cable 3x16+1x10) Mett 100 Korea
9 Electrical box Gox 1 Vietnam
10 Stand Conveyor Pcs 25 ZSV
11 Roof Panel Carridge Pcs 30 ZSV
Safety      
1 Safety Clothers Pcs 30 France
2 Universal Harness (1008833 size M) Pcs 17 France
3 Rope Lanyard 2m with G) Pcs 17 France
4 Safety rope (14mm Polyamide Rope) Pcs 4 France
5 Helmet Pcs 16 Vietnam