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TECHNICAL SPECIFICATION

SHOP FABRICATED STRUCTURAL STEEL WITH


HIGH STRENGTH BOLTED FIELD CONNECTIONS
S15-1F
DATE: 01 AUG 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 1 OF 5

TABLE OF CONTENTS

Section Title Page No.
1. GENERAL ........................................................................................................................... 1
1.1 Scope.................................................................................................................................. 1
1.2 KBR Documents, Codes, and Industry Standards ................................................................... 1
2. DESIGN............................................................................................................................... 2
2.1 General ................................................................................................................................ 2
2.2 Connections ......................................................................................................................... 2
2.3 Bracing ................................................................................................................................ 3
2.4 Bolting ................................................................................................................................. 3
3. MATERIALS........................................................................................................................ 3
3.1 General ................................................................................................................................ 3
3.2 Structural Steel ..................................................................................................................... 3
3.3 Bolting ................................................................................................................................. 4
4. FABRICATION .................................................................................................................... 4
4.1 General ................................................................................................................................ 4
4.2 Welding ............................................................................................................................... 4
4.3 Welding Electrode and Filler Metal Limitations ........................................................................ 5
4.4 Surface Preparation and Shop Coatings ................................................................................ 5

1. GENERAL

1.1 Scope

1.1.1 This Specification covers the requirements for shop fabricated structural steel including various field
connected high strength bolted structures or component parts.

1.1.2 All materials, design, and fabrication, including any examination and testing shall be in accordance with
the requirements and limitations of the AISC "Manual of Steel Construction".

1.2 KBR Documents, Codes, and Industry Standards

The following documents are referenced herein and form part of the Order. Additional KBR documents, when
applicable, will be listed on the Requisition. The issue dates of KBR documents shall be as specified in the
Requisition. Current editions of the industry standards including all mandatory addenda in effect at the time of
the order shall apply unless otherwise indicated.

KBR DOCUMENTS
S15-1PS, "Purchasing Requirements for Shop Fabricated Structural Steel with High Strength Bolted Field
Connections"
V42-6TS, "Coating and Galvanizing Requirements for Structural Steel"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
ASTM A6/A6M, "General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling"
ASTM A36/A36M, "Carbon Structural Steel"
ASTM A53, "Pipe, Steel, Black, and Hot-Dipped, Zinc-Coated, Welded and Seamless"
ASTM A307, "Carbon Steel Bolts and Studs, 60 000 psi Tensile Strength"
ASTM A325, "Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength"
ASTM A325M, Structural Bolts, Steel, Heat Treated 830 MPa Minimum Tensile Strength (Metric)
ASTM A490, "Heat-Treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength"
ASTM A500, Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
ASTM A501, Hot -Formed Welded and Seamless Carbon Steel Structural Tubing
ASTM A992/A992M, "Structural Steel Shapes"
ASTM A1011, "Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and
High-Strength Low-Alloy with Improved Formability"
TECHNICAL SPECIFICATION

SHOP FABRICATED STRUCTURAL STEEL WITH
HIGH STRENGTH BOLTED FIELD CONNECTIONS
S15-1F
DATE: 01 AUG 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 2 OF 5


AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC, "Manual of Steel Construction, Load and Resistance Factor Design", 2nd Edition

AMERICAN WELDING SOCIETY (AWS)
AWS A2.4, "Standard Symbols for Welding, Brazing, and Nondestructive Examination"
AWS A5.1, "Carbon Steel Electrodes for Shielded Metal Arc Welding"
AWS A5.5, "Low Alloy Steel Electrodes for Shielded Metal Arc Welding"
AWS A5.17/A5.17M, "Carbon Steel Electrodes and Fluxes for Submerged-Arc Welding"
AWS A5.18, "Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding"
AWS A5.20, "Carbon Steel Electrodes for Flux Cored Arc Welding"
AWS D1.1, "Structural Welding Code - Steel"

2. DESIGN

2.1 General

2.1.1 All designing and detailing by the fabricator shall be in accordance with the AISC "Manual of Steel
Construction.

2.1.2 The symbols used for designating welds shall be in accordance with AWS A2.4.

2.1.3 The elevations shown on design drawings or tabulations are to the top of the steel or the bottom of the
flooring unless otherwise specified.

2.1.4 Except as modified by drawings, connections shall be designed and detailed as follows:

a. Shop connections shall be welded. Bolts may be used for shop connections only where welding is
impractical.

b. Field connections shall be bolted.

c. Bevel washers shall be furnished for structural and high strength bolted connections to sloping flanges, and
when required for flanges for diagonal tie rod bracing connections.

2.2 Connections

2.2.1 The fabricator shall design and detail all parts of all connections not detailed on the Purchaser's design
drawings and Technical Standards. The Purchaser's design drawings will indicate the design loads to be used
by the fabricator for the design and detailing of connections except as indicated below.

a. Unless otherwise indicated on the Purchaser's design drawing, all beam connections shall be designed as
double angle beam connections. These connections shall be designed to sustain half the maximum
factored uniform load for a fully laterally supported beam.

b. Unless otherwise indicated on the Purchaser's design drawings, all connections for diagonal bracing and
connections at the ends of tension or compression members in trusses shall be designed to develop the
force due to the design load; but not less than 50% of the design tensile strength of the bracing member or
6 kips (27 kN), whichever is greater. The design tensile strength shall be calculated using the gross
cross-sectional area of the member. Working points for designing and detailing the connections shall be as
shown on the Purchaser's design drawings.

c. High strength bolts shall be tightened in accordance with AISC "Specification for Structural Joints Using
ASTM A325 or A490 Bolts, Section 8d, Paragraph (1).
TECHNICAL SPECIFICATION

SHOP FABRICATED STRUCTURAL STEEL WITH
HIGH STRENGTH BOLTED FIELD CONNECTIONS
S15-1F
DATE: 01 AUG 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 3 OF 5


2.2.2 Bolted connections for ladders, handrail posts, stair treads and stringers, purlins, and girts shall be made
with structural bolts. All other bolted connections shall be made with high strength bolts.

2.2.3 High strength bolted connections shall be designed as bearing-type connections with threads included in
the shear plane.

2.2.4 The connections shall be detailed to minimize blockouts in shop applied fireproofing.

a. Single plate connections shall be used for the floor beams of 8 inch (200 mm) or less nominal depth, unless
noted otherwise on the design drawings.

b. Gusset plate for vertical or horizontal bracing members shall extend outside of the fireproofing.

c. Handrail connections to the fire proof columns shall be minimized. Posts shall be provided to support the
handrail at the face of the fire protected column.

2.3 Bracing

Suitable deductions to provide for draw shall be made in the computed lengths of all diagonal angle bracing
longer than 10 feet (3 m).

2.4 Bolting

2.4.1 Structural bolts shall be 5/8 inch (M16) minimum diameter unless limited by the size of the connected
parts. Stair tread to stringer connections shall be by 5/8 inch (M16) diameter structural bolts.

2.4.2 High strength bolts shall be 3/4 inch (M20) minimum diameter unless otherwise specified on the design
drawings.

2.4.3 Bolt heads shall be of the heavy semi -finished hexagon series.

3. MATERIALS

3.1 General

3.1.1 Except as otherwise specified herein or on the design drawings, all materials shall be new and conform to
AISC specifications.

3.1.2 Material subject to welding shall be of weldable quality.

3.1.3 No substitution of materials, sizes, or shapes shall be made without the prior written approval of the
Purchaser.

3.2 Structural Steel

3.2.1 Structural steel wide-flange shapes, including WTs, shall conform to ASTM A992/A992M, Grade 50 and
its general requirements specification ASTM A6/A6M, or other equivalent or superior quality steel. All other
structural shapes, plates, and bars shall be in accordance with ASTM A36/A36M, unless specified otherwise on
the design drawings.

3.2.2 Steel pipe for structural applications shall conform to ASTM A53, Type E or S, Grade B, open hearth or
basic oxygen steel.
TECHNICAL SPECIFICATION

SHOP FABRICATED STRUCTURAL STEEL WITH
HIGH STRENGTH BOLTED FIELD CONNECTIONS
S15-1F
DATE: 01 AUG 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 4 OF 5


3.2.3 Structural tubing for structural applications shall conform to ASTM A501 or ASTM A500 Grade B.

3.2.4 Unless otherwise shown on the design drawings, flooring shall be open type steel grating having 1 inch
deep x 3/16 inch thick (25 mm x 5 mm) bearing bars with non-skid cross bars, pressure welded in a rectangular
pattern and shall conform to ASTM A1011.

3.3 Bolting

3.3.1 Structural bolts and nuts shall conform to ASTM A307 Grade B and high strength bolts shall conform to
ASTM A325, Type I for service temperatures above -20
o
F (-29
o
C). For service temperatures below -20
o
F
(-29
o
C), appropriate austenitic bolting shall be specified in the Order.

3.3.2 The fabricator shall supply all bolts, nuts and washers necessary for erection purposes and permanent
field connections. The fabricator shall supply the required number of bolts, nuts, and washers for each length
and diameter plus 10% excess.

4. FABRICATION

4.1 General

4.1.1 Component groups marked "Shop Assembled Piece" (SAP) or "Modular" on the design drawings shall be
shop assembled.

4.1.2 Ladders with cages and top rails; handrailing with top rail, mid rail and posts; and platforms shall be shop
fabricated and shop assembled to the extent shown on the Purchaser's design drawings and Technical
Standards.

4.1.3 All columns except angle posts shall have milled (machined) ends for full bearing at splices and base
plates.

4.2 Welding

4.2.1 All welding shall be done in accordance with AWS D1.1. All welding procedures submitted in accordance
with Paragraph 3.3.3 of S15-1PS shall be qualified by performing procedure qualification tests; the AWS
prequalified procedures shall not be acceptable.

4.2.2 Electroslag and electrogas welding procedures shall not be used.

4.2.3 All welding shall be done by the Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW),
Gas Metal Arc Welding (GMAW), or Submerged Arc Welding (SAW) process.

a. For SMAW, FCAW, and GMAW, all vertical welding shall be done in the vertical up progression.

b. GMAW using the short circuiting mode of transfer shall not be used on base metal thicknesses in excess of
3/8 inch (10 mm), except for root passes.

c. For SAW, voltage sensitive (active) fluxes shall not be used for multi-pass welding.

4.2.4 The automatic welding procedure shall be qualified using the same material, process, and type of
equipment to be used for production. If the machine operator performing the production welding is not the same
operator used in qualification of the procedure, he shall be qualified separately.

TECHNICAL SPECIFICATION

SHOP FABRICATED STRUCTURAL STEEL WITH
HIGH STRENGTH BOLTED FIELD CONNECTIONS
S15-1F
DATE: 01 AUG 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 5 OF 5

4.2.5 Welding starts and stops on all passes shall be held to a minimum. When starts and stops are
unavoidable, each position shall be properly conditioned before proceeding with the adjacent welding. The use
of starting and stopping plates is recommended.

4.3 Welding Electrode and Filler Metal Limitations

4.3.1 Electrodes for manual Shielded Metal Arc Welding (SMAW), shall conform to AWS A5.1 or
AWS A5.5; E70XX.

4.3.2 Filler metal for Flux Cored Arc Welding (FCAW) shall conform to AWS A5.20; E70T-1 through E70T-6.
E70T-G filler metal shall not be used without the written approval of the Purchaser.

4.3.3 Filler metal for Gas Metal Arc Welding (GMAW) shall conform to AWS A5.18; E70S-1 through E70S-6.
E70S-G filler metal shall not be used without the written approval of the Purchaser.

4.3.4 Electrode-Flux classifi cations for Submerged Arc Welding (SAW) shall conform to AWS A5.17/A5.17M;
F72-EXXX.

4.4 Surface Preparation and Shop Coatings

All structural steel shall be coated in accordance with V42-6TS. Any surface inaccessible to coating shall be
sealed for moisture by seal welding.