06 STRUCTURAL STEEL WORKS

TS/S/06/1
 CONTENT PAGE

1. GENERAL TS/S/06/3

1.1 Summary TS/S/06/3

1.2 Applicable Specifications and Codes TS/S/06/3

1.3 Submittals TS/S/06/4

2. PRODUCT TS/S/06/5

2.1 Material TS/S/06/5

3. EXECUTION TS/S/06/6

3.1 Fabrication TS/S/06/6

3.2 Welding TS/S/06/6

3.3 Connection TS/S/06/7

3.4 Protection TS/S/06/8

3.5 Erection TS/S/06/11

3.6 Connection of Steel Element against Concrete Structures TS/S/06/13

3.7 Fireproofing Protection TS/S/06/14

3.8 Miscellaneous Structural Steel Platform/Skeleton/Framing etc TS/S/06/14

3.9 Weld Tests and Inspection TS/S/06/15

TS/S/06/2
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1. GENERAL

1.1 Summary

a. The work covered by this section of the Specifications consists of furnishing all labor, plants,
tools, equipment’s, materials and performing all operations in connection with the fabrication,
assembly, transportation, delivery, installation, and/or erection of all miscellaneous structural
steel works including all related items, appurtenances and shop coats or protective paint,
complete in every respect in strict accordance with this section of Specification, applicable
drawings, and subject to the terms and conditions of the Contract.

b. The works shall comprise the design of connections, testing, detailing, supply and fabrication,
transportation to site and erection of all the structural steelwork, and all sundry work as shown
on the contract drawings referred to in this contract document.

c. The Contractor is deemed to have allowed in his Tender Sum for all the interfacing and co-
ordination work with other sub-contractors and other direct Specialist Contractors engaged by
the Employer for installing their works.

d. Without intending to limit and/or restrict the volume or generality of the foregoing work, and
solely for convenience of CONTRACTOR, it comprises the following items and works:

i. All anchors, hangers, clamps, pipes, bolts, nuts, washers, clips, straps, brackets,
stirrups, pins, rods, rollers, dowels, and any other securing and anchorage devices
required and necessary for the setting and proper securing of all miscellaneous metal
and iron work.

ii. Ladders complete with securing devices and anchors for face securing on building - in
masonry walls.

iii. Stair Well Railings.

iv. Misc. Iron Pipe Railings.

v. Roll-up Steel Shutters.

vi. Gratings.

vii. Protection screens over openings in roof.

viii. Misc. Structural Beams, Angles and Channels platform, columns, framing system etc.

ix. The primer and/or shop coat protective painting of all work specified under "Painting".

1.2 Applicable Specifications and Codes

The latest editions of American Institute of Steel Construction (AISC), relevant American
Standard of Testing of Materials (ASTM), American Iron and Steel Institute (AISI) and/or British
Standards Specifications (BSS) as determined by the EMPLOYER form a part of this section
of Specification as though written in and/or attached hereto, and are intended to be used as a
guide only to provide a minimum standard of kind, quality and finish. EMPLOYER reserves the
right to determine compliance and/or acceptability of the material and/or standards.

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1.3 Submittals

a. The CONTRACTOR shall prepare all necessary shop and erection drawings covering the
structural steel to be furnished under these specifications. No fabrication and erection shall be
taken in hand until these drawings have been approved by the EMPLOYER.

b. The drawings submitted shall be modified as and when necessary and, if directed by the
EMPLOYER, resubmitted for further review.

c. Calculations and drawings submitted by the CONTRACTOR shall be prepared by a qualified

and competent professional approved by the EMPLOYER. The cost for all such work and
drawings shall be borne by the CONTRACTOR.

d. Shop drawings submitted shall include but not limited to the following:

i) Grades of Steel
ii) Identification marks of members
iii) Dimensions
iv) Size
v) Arrangement and Weight of members
vi) Position of Members relative to existing grid lines
vii) Setting out
viii) Elevation and details of support bases
ix) Framing to support access platforms
x) Cat Ladders
xi) Supports for M&E services suspended from the roof structure
xii) Location and size of openings, slots and holes
xiii) Requirements for any other drilled holes for attachment of other
parts of construction or erection purposes
xiv) Type, size and location of shop and field connections
xv) Welding sequences
xvi) Cleaning requirements prior to painting
xvii) Dry Film thickness of applied painting system

e. Delays caused by late submission of such drawings or modifications thereto arising from
repeated errors, unacceptable details, unclear or insufficient information will under no
circumstances are construed as reasons for a request for an extension of time to the contract.

f. Approval by the EMPLOYER of the shop drawings does not relieve the CONTRACTOR of the
responsibility for the accuracy of detailed dimensions on the shop drawings, nor the general fit-
up of parts to be assembled in the field.

g. The CONTRACTOR shall be responsible for all financial and time consequences arising out of
errors, omissions or non-clarity in such drawings or delays in submission thereof.

h. Manufacturer's test certificates for all steel used for fabrication or for bolts for the works shall
be supplied.

i. Independent analysis and tests on the materials may be made from time to time by and analyst
or testing laboratory selected by the EMPLOYER in order to check the works analysis and tests.

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2. PRODUCTS

2.1 Material

a. All structural steel section sections and plates shall be S355 with minimum yield strength of 345
N/mm2 conforming to the relevant product standard specified in BS 5950:200, unless otherwise
specified.

b. Stainless steel where specified shall conform to AISI Type 304.

c. Steel shall be free from defects impairing strength, durability or appearance, and of best
commercial quality for purposes specified. All steel made of new materials, with structural
properties to sustain safety or with stand strains and stresses to which normally subjected, true
to details, clean, straight, with sharply defined profiles, curved work to true radii, and, unless
otherwise particularly noted, with smooth finished surfaces.

d. Fastenings which are exposed to be of the same materials, color and finish as metal to which
applied, unless otherwise shown on the drawings or specified.

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3. EXECUTION

3.1 Fabrication
The fabrication of the steel work shall be in accordance with latest AISC/BS Specification for the design
and fabrication, or acceptable equivalent.

Fabrication of all structural steelwork including welding, trimming, painting and site splicing shall be
inspected and approved by EMPLOYER. Unless otherwise approved by EMPLOYER, no splicing is
allowed within a member. Unless otherwise stated, all splicing shall provide full moment and shear strength
capacity.
Structural steel elements shall be cut by sawing, shearing, cropping or machine flame cutting. There shall
be no field cutting of structural steel members without the prior approval of the EMPLOYER. Surface cut
manually shall be ground back to clear smooth edges and shall be done to the approval of the EMPLOYER.
Manual thermal cutting of edges to be welded shall not be permitted.
Round holes for bolts, fasteners, or pins shall either be drilled or punched. No site drilling of holes is
permitted. Slotted holes shall either be punched in one operation or formed by drilling two holes and
completed by cutting. All matching holes for fasteners or pins 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.
The temporary steel supports for steel truss fabrication are to be adjustable in order to accommodate the
required pre-camber as specified.

3.2 Welding
All welding shall be carried out in accordance with BS EN 1011 and BS 5950, Part 2. Electrodes shall
comply with the latest requirements of BS EN ISO 2560 – Welding consumables. Covered electrodes
for manual metal arc welding of non-alloy and fine grain steels. All welding consumables used for the
fusion welding to steel castings shall comply with BS 4570.
All welding is to be electric arc process. All surfaces to be welded shall be suitably wire-brushed to
ensure no traces of scales, rust, paint, etc. remain before commencement of welding. Whenever
possible, the welding is to be laid in the down hand position. Where a weld is laid in several runs, after
laying each run the weld is to be chipped and wire-brushed to ensure the removal of slag. Welds are to
be laid in a suitable sequence to avoid any distortion of members being welded. Final completion of all
welds entails thorough cleaning or grinding off to the EMPLOYER’s satisfaction.
Welds exposed to view shall be ground flush and dressed smooth to match the finish of the adjoining
surfaces. Where welds are required to be flush, the metal edges shall be undercut. Weld splatter and
welding oxides shall be removed to the satisfaction of the EMPLOYER.
Class B Electrodes shall be used when metal arc welding steel to BS EN ISO 2560, Grade 43, of
thickness up to and including 50mm unless specified otherwise.
Class B(H) hydrogen controlled electrodes shall be used for the metal arc welding of steel to BS 7668
Grade 50 and 55. For the metal arc butt welding of steel over 25mm thick the root run shall be made
with a class B(H) hydrogen controlled electrode or by a low-hydrogen welding process.
Where flux-cored arc welding (generally considered to be a low –hydrogen welding process) is used,
the CONTRACTOR shall submit the manufacturer’s specification for the flux-cored electrodes, which
shall comply with the approved list of classification for such welding process.
Electrodes for the manual metal arc welding of steel Grades 50 and 55 to BS 7668 shall be type E51
complying with BS EN ISO 2560.

All electrodes shall be used strictly in accordance with the electrode manufacturer’s recommendations

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Class B(H) hydrogen controlled electrodes shall be carefully dried and used directly from an oven or
heated quiver.
All low hydrogen electrodes shall be stored in hermetically sealed containers. Immediately after removal
from the containers, or from the drying ovens, and before use, electrodes shall be stored in ovens at a
temperature of at least 120 degree Celsius.
All welding is to be carried out in an approved environment and if necessary additional protection to be
provided as directed by the EMPLOYER. All joints are to be torch dried before welding in damp
environment.
All welders shall be fully competent and have passed or be capable of passing suitable tests as given
in BS EN ISO 9606 or BS 4872 and BS 5950. However, the EMPLOYER shall have the right to select
at least six (6) of these qualified welders to be tested in accordance with the contract specifications at
the CONTRACTOR’s cost. In the event of failure to pass the test, the CONTRACTOR shall remove that
welder from the project and shall replace him with a properly qualified welder, who shall also be required
to undergo qualifying tests at the CONTRACTOR’s cost.
Weld metal deposited by an automatic or semi-automatic process shall have mechanical properties not
less than the minimum specified for the weld metal deposited by electrodes complying with BS EN 2560.
The sequence of welding shall be suitable for the work and the EMPLOYER's approval to the same
shall be obtained before welding is commenced.

3.3 Connection
SITE connections will be in accordance with AISC/BS Specification, and will generally be welded and/or
bolted. The CONTRACTOR shall supply all nuts and bolts etc. including spares and service bolts for
the efficient erection of the structure.

All bolts, nuts and washers shall be of strength grade 4.6 with 2 mm clearance holes to BS 4190 or
grade 8.8 complying with BS 3692, unless otherwise specified. Steel nuts shall be of at least the
strength grade appropriate to the grade of bolt or other threaded element with which they are used.
Plain washers used in conjunction with the bolts and nuts shall comply with BS 4320. High strength
friction grip bolts nuts and washers shall comply with BS 4395.
Where necessary the connected parts shall be firmly drawn together. Steel packing plates shall be
provided where necessary to ensure that the total remaining gap between adjacent surfaces does not
exceed 2 mm. Packs, shims and other supporting devices shall be flat, of adequate strength and rigidity
and not larger than necessary. For corrosion protection, packs, shim and other supporting devices shall
be treated similar to the parent metal.
All bolts shall have their threads excluded from the shear plane. Unless specifically specified otherwise,
the length of bolt shall be such that at least one clear thread shows above the nut after tightening, and
at least one thread plus the thread run out is clear between the nut and the unthreaded shank of the
bolt.
For connection detail submitted by the CONTRACTOR, a combination of bolts and welds is not
permitted for force transmission in the same faying surface.
Where connection of aluminum parts are specified in the drawing, stainless steel bolts and nuts are to
be used.
HSFG bolt shall be tightened by mechanical or electro-mechanical means with a suitable means of
checking the final preload required on the bolts. Mill certificates for such bolts shall be submitted and
tests of both the bolts and the calibration of the torque tightening means shall be conducted by the
CONTRACTOR at his own cost to confirm the mechanical properties of the material, the minimum
shank tension and shear force of such bolts.
The CONTRACTOR shall note that the tightening of bolts shall conform to the following procedures and
shall be conducted in two stages, an initial and a final. The CONTRACTOR shall provide the
EMPLOYER adequate means and apparatus to physically determine the torque in each bolt.

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i) Initial tightening:
Bolts shall be installed in all holes of the connection and initially brought to a snug tight condition.
Snug tight is defined as the tightness that exist when ply of the joint are in firm contact. This
may be attained by a few impacts of any impact wrench or the fully effort of a man using an
ordinary wrench.
Snug tightening shall progress systematically from the most rigid part of the connection (around
center of the joint) to the free edges and then the bolts of the connection shall be re-tighten in
a similar systematic manner as necessary until all bolts are simultaneously snug tight and the
connection is fully compacted.

ii) Final Tighten

Following the initial operation all bolts in the connection shall be tightened further by the electric
wrench engaging both the bolt and nut until the torque control groove of the bolt shear off, or
alternatively a calibrated torque wrench could be used to ensure that the specified torque has
been achieved, progressing systematically from the most rigid part of the connection to the free
edges in a manner that will minimize relaxation of previously tightened fasteners prior to final
twist-off or yielding of the control of the individual fasteners.
High strength friction grip bolts, where used, shall be installed and tightened in accordance with
the minimum shrank tension as specified in BS 4604.
Joints in crane rails shall be fitted with a total clearance not exceeding 1/8" (3 mm). Crane rails
shall be bolted to crane beams or girders with malleable steel clips. Rails shall be aligned and
leveled to the approval of the EMPLOYER and to within the limits laid down by the crane
manufacturer.

iii) Washers

Washers shall be provided at slotted holes and elsewhere where necessary.

3.3 Protection
Protective work shall be carried out in accordance with the relevant clauses of BS 5493.
All steel surfaces shall be protected from corrosion by an approved heavy-duty protective coating paint
system, which shall comply with the following requirements:
a) All paints forming part of any one painting system shall be obtained from the same manufacturer.
Paint shall be supplied in sealed containers of a capacity, unless otherwise approved by the
EMPLOYER, of not more than 20 litres. Each container shall be clearly marked with the
manufacturer’s name, paint type, colour, production batch number, date of manufacture and pot
life.
b) Prior to the commencement of painting of steelwork, the CONTRACTOR shall submit for the
EMPLOYER’s approval a full specification of the paint or paints he proposes to order, together with
the name of the manufacturer whose paint he proposes to use. If instructed to do so by the
EMPLOYER, he shall supply liquid samples of the various paints concerned for examination and
testing. No paint shall be used without the prior approval of the EMPLOYER.
c) Primers and paints shall be applied strictly and shall be carried out by skilled painters under the
supervisor provided by the paint supplier.
Paints shall be used strictly in order of delivery from the manufacturer. Paint shall not be used after the
expiration of the pot-life stipulated by the manufacturer, and paints of limited pot-life shall not be mixed
with fresh paint or have thinners added to them.
Painting processes and methods shall be to the approval of the EMPLOYER. All tools, solvents and

plant used shall be such as to obtain the best possible results and shall be maintained in good condition

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throughout.
Wherever practicable, successive coats in paint systems should differ in colour. However,
manufacturer’s recommendations in respect of the colours of the undercoats and first coat should be
observed.

Preparation of Surfaces at Works

i. Steel work which is to be permanently encased in concrete shall be given a cement wash after it
has been blast cleaned free from all mill scale, rust and other contamination.

ii. All other steel work shall be blast cleaned free from all mill scale, rust and other contamination.

iii. Maximum profile height of the blasted surface shall not exceed 1 mm.

iv. All surface defects likely to be detrimental to the painting system shall be removed.

v. All fins at saw cuts, burrs and sharp edges shall be similarly removed. Where extensive grinding
has been necessary, the dressed areas shall be re-blasted to remove all rust and provide adequate
paint key.

vi. After blasting, all spent shot or grit must be removed by vacuum cleaner or, if such equipment is
not available, by airline and brush.

vii. After blast cleaning, steel work shall be immediately protected before the surface has time to re-
rust and in any case within four hours, with one spray coat of an approved primer.

viii. After fabrication, weld spatter should be chipped away and joints re-blasted by tools and cleaned
to a high standard.

ix. All welds, corners, crevices, etc. should then be painted by brush.

Preparation of Surfaces at Site

Areas of mechanical damage shall be thoroughly cleaned and painted in accordance with specification
for "Painting".

Materials & System application

Blast clean to Swedish Standard SSC-SP10, surface amplitude 50-100 microns.

Two-pack epoxy zinc rich primer
(Coating A): 70 microns
Two-pack epoxy micaceous iron oxide high-build primer
(Coating B):100 microns
Ensure steelwork is free of contamination by solvent cleaning to the EMPLOYER's approval and
washing with clean, fresh water.

Two-pack epoxy high build mastic - colour as directed

(Coating C):100 microns
Two-pack polyurethane finish-colour as directed
(Coating D): 65 microns
Total minimum dry film thickness : 0.30 mm

Repair Procedure

Power tool clean to SSPC specification SSP-SP3-63 or Power Tool Cleaning to give surface finish St 3

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grade to Swedish Standard SIS 05 59 00.
Touch up with Surface Tolerant Epoxy Primer (Coating E).

Painting of works shall be in accordance with Technical Specifications – Architectural works,

SECTION C5: PAINTING TO METAL SURFACES (ESF)

APPLICATION
Except where otherwise specified or where agreed by the EMPLOYER, protective treatment shall be
carried out in the steelwork fabricator’s works after fabrication. Shop treatment shall be carried out in
a weather-proof structure under clean, dry conditions.
Steelworks of which the application of treatment has started shall be protected from external
atmospheric conditions until completion of the treatment and the subsequent curing period.
The surface preparation to be made good at the damaged or any welded part of the steel structure at
the construction site shall be power tool to St3 and primed with an approved surface tolerant epoxy
primer to the thickness of 75 microns before top coating as specified
At the shop after the steel is primed with an approved inorganic zinc rich primer, it shall be immediately
sealed with an approved epoxy primer/tie coat to prevent the primer from forming zinc salts.
The surface after preparation within 200mm of any parts of the steelwork to be welded shall be treated
with an approved weldable self-curing inorganic zinc primer, which has no deleterious effects on the
production of satisfactory welds and subsequent paintwork.
For fraying surfaces connected by high strength friction grip bolts, the surface after preparation shall
be treated with an approved inorganic air cured zinc silicate primer which must have proven laboratory
records that surfaces treated with the primer will not affect the full function of the friction grip bolted
connections (static frictional coefficient well above 0.45).
Each coat of paint shall be applied by airless spray or other methods approved by the EMPLOYER, so
as to produce a continuous film of paint of uniform and even thickness. Successive coats shall be of a
different shade so that the coverage of each coat is clearly visible. Each coat shall be thoroughly dry
and cleaned of all dust and loose paint before the application of a further coat. Where required by the
EMPLOYER, surfaces shall be cleaned by washing down with a solution of approved liquid detergent,
followed by rinsing with clean, fresh water.
The CONTRACTOR must ensure that the coating system he proposes must be free from pinholes and
defects during application and must suit their fabrication process with respect to the maximum over-
coating intervals between the respective coats of paint. The CONTRACTOR is required to conduct paint
trials using the same labor and equipment that he proposed for the structural steelwork before the paint
system can be approved.
If the painting trial is unsuccessful and disapproved by the EMPLOYER, the CONTRACTOR has to
replace the whole paint system at his own cost and conduct the re-trials at his own cost.
The machined ends of compression members and machined interfaces shall be protected by a single
coat of pre-fabrication primer after machining and then masked out on the compression surfaces to
prevent overcoating with the finishing coats and to protect the machined surface during the period
between completion of the fabrication and erection. Masking shall be removed immediately prior to
erection.
The CONTRACTOR shall arrange for the services of at least two full time representatives from the paint
manufacturer. They shall visit the site before the start of the cleaning and coating operations to advise
the CONTRACTOR’s personnel on the painting procedures. Thereafter they shall be stationed full time
at the shop and construction site to ensure the coatings are applied according to the Specification.
Within 3 months of the award of the contract, the CONTRACTOR shall carry out such paint application
procedure trials using the same labor and equipment proposed for the steelwork, on samples of the
steelwork and plates. The samples used in the trials if approved shall be the minimum accepted
standard for the works.
The CONTRACTOR shall take due care and preventive precautions during protective treatment and in

subsequent transport, storage and erection to ensure that damage to the paint coating system is kept

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to the absolute minimum. After blasting and before painting, all steelwork shall be supported on proper
rigid stand at a minimum height of 600 mm above the floor of the workshop.
Where welding, handling, erection process damage parts of steelworks, the CONTRACTOR shall
submit detailed proposals for repair to the full coating in accordance to the manufacturer’s
recommendation to the EMPLOYER for approval.

STORAGE
Where it is necessary to store painted fabricated steelwork prior to erection, it shall be kept clear of the
ground by at least 500mm and stacked in such a manner as to ensure that no pools of water or dust
accumulate on the surfaces. Suitable packing shall be provided between layers of stacked steelwork.
Covers, when provided, shall be well ventilated. Coated surfaces shall not be in contact.
Steelworks delivered to site, which, in the opinion of the EMPLOYER, is not in accordance with this
Specification for cleaning, and shop painting shall be returned to the steelwork fabricator’s works. The
existing painting system shall be completely removed and the full system re-applied to the approval of
the EMPLOYER.

STANDARD BOLTS, NUTS AND WASHERS

Unless otherwise permitted by the EMPLOYER, all bolts, nuts and washers shall be hot dipped galvanized
in accordance with BS EN ISO 1461 to 125 microns thickness and shall be further prepared and coated to
the same standard as the adjacent surfaces. All exposed HSFG bolts are to be atmospheric corrosion
resistant and shall be painted in accordance to paint manufacturer’s recommendation to match the finishing
coat of the steel structure.
All contact surfaces shall be thoroughly cleaned by hand wire brushing or similar means immediately
prior to being brought together.
After tightening, bolt heads, nuts and washers shall be thoroughly cleaned and exposed surfaces
painted with an approved two-packed non-phenolic etch primer followed by the appropriate full system
or primers and paints.

3.2 Erection

a. Erection Procedure

The CONTRACTOR shall engage a qualified and competent professional, subjected to the approval
of the EMPLOYER, to be fully responsible for the design and supervision of the temporary works
to ensure that the construction of the permanent works are carried out in a safe manner.

Erection procedure shall include methods, sequence of erection of temporary columns, beams, guy
ropes, bracing sizes, connection details, design calculations and type of lifting / launching
equipment proposed for all the structural steel works.

The CONTRACTOR shall be responsible for the control of all erection procedures and sequences
especially with relation to temperature differentials, erection tolerances, and with respect to
structural steel framing into reinforced concrete walls, beams or columns.

All additional steel required by the CONTRACTOR for erection purposes and site access of
stockpiled materials shall be provided at no cost to the Employer. The CONTRACTOR shall remove
all such additional steel, unless approved by the EMPLOYER in writing.

No loading on the permanent works in excess of the designed imposed loads shall be placed on
any portion of the permanent structure without the written permission of the EMPLOYER.

The CONTRACTOR shall be responsible to provide additional temporary bracing and supports as
required throughout the erection process until the steel members are fully connected and stable.

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The CONTRACTOR shall submit to the EMPLOYER. for approval design calculations to verify the
adequacy of permanent works or any parts thereof during construction from the use of such cranes,
temporary steel towers/supports and any heavy loads on the permanent works. Any additional
provisions required to strengthen the constructed floor shall be deemed to be included in the
contract sum.

The CONTRACTOR shall also co-ordinate with other Sub-contractors or direct contractors to
ensure that the floors required to be strengthened will not affect the overall program.

The CONTRACTOR shall make his own arrangement to strengthen the access road, if so required,
to accommodate his heavy lifting cranes to lift other cranes, roof trusses, generator sets, welding
sets, temporary steel supports and temporary steel towers to the building floor.

The CONTRACTOR shall make good any parts of the permanent works to which he has had
embedded any temporary attachments for bracing of his temporary steel towers, etc. to the
satisfaction of the EMPLOYER.

Erection procedure submitted shall be illustrated by schematic drawings indicating items such as:
i) Method and sequence of assembling the structural steelworks on the ground.
ii) Method and sequence of lifting and hoisting the assembled structures from
the round and / or temporary supports to its final position.
iii) Temporary guy ropes and bracings to structural steelworks during erection.
iv) Temporary columns to support the structural steelworks, where required.
v) Identification of any of the items (i) to (iv) above that affects the permanent
structure.
The submission shall not relive the CONTRACTOR of his responsibilities for providing proper
methods, equipment, workmanship and safety precautions as well as any requirements of
submission to the local authority with regards to temporary works.

b. Joint Welding Procedures

The CONTRACTOR shall submit to the EMPLOYER joint welding procedures prior to
commencement of any welding works. Upon approval, welding procedures and sequences shall
be followed without deviation.
Details of proposed welding procedure shall be accompanied by diagrams showing the built-up of
all main welds, together with the details of the manufacture, classification, code (as defined in BS
EN 2560) and the size of electrodes to be used.
A checklist of the weld joints, positions, thickness, and planned processes for the welds shall be
identified and the CONTRACTOR shall provide a written welding procedure specification for each
type of weld and submit to the EMPLOYER for review to ensure that they are rational and fall within
the welding codes.
Welding procedure shall be such that distortion is reduced to a minimum and local distortion is
rendered negligible in the final assembly.
Approval of the welding schedule and procedure shall not relieve the CONTRACTOR of his
responsibility for the correct welding and for the minimization of distortion in the finished structure.

c. Erection Marks

Before any steelwork leaves the CONTRACTOR’s workshop it shall be suitably marked in
accordance with the approved shop and erection drawings and according to an approved marking
plan. Erection marks shall be clearly painted on the work, and all members weighing over 5 tons

shall have the weight clearly indicated.

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d. Foundation Bolts

Foundation bolts shall be sent to the SITE in good time to enable them to be built into the
foundations together with any other steelwork that is required to be built into the concrete or block
work. Any templates, that are necessary for the proper positioning of the bolts, shall also be
supplied.

e. Accuracy of Setting Out

The CONTRACTOR shall be responsible for the correct lining and leveling of all steelwork on SITE
and for the accurate plumbing of the stanchions. In addition, he shall, before the concrete
foundations are cast, check the positioning of the foundations bolts.

f. Lining Up

The bolting up of connections shall be not be carried out until a sufficient portion of the structure has
been erected and temporarily connected up to ensure that there shall be no straining of members in
the erection and lining up of the remainder of the structure.

g. Stability of Structure

The CONTRACTOR shall be responsible for the stability of the steelwork at all stages of its erection
on SITE and shall take all necessary measures by the addition of temporary bracing and guying to
ensure adequate resistance to wind, accidental loading etc.

h. Grouting

The methods of grouting the column bases shall be to the approval of the EMPLOYER and shall be
such as to ensure a complete uniformity of contact over the whole area of the steel base.

No grouting or concreting shall be done until the EMPLOYER has approved the alignment level, and
plumbing of the steel work.

Steel packing for leveling up stanchions shall not be larger than is necessary for their purpose and
they shall not protrude unduly from the stanchion base. They shall be grouted in and the grout shall
totally enclose them.

i. Tolerance

The maximum tolerance permitted for line and level is 1/8" (3 mm) on any part of the structure, nor
shall any vertical member be more than 1/8" (3 mm) out of plumb per 20 ft (6 M approximately)
height.

3.6 CONNECTION OF STEEL ELEMENTS AGAINST CONCRETE STRUCTURES

CONTRACTOR shall note that before any connection can be made between steel elements &
existing concrete structures, all rendering and loose and deteriorated concrete must be removed
and any dust, dirt etc. on the concrete surface shall be brushed off and removed by spraying the
concrete surface with water.
Where drilling of holes are required for fixing of anchor bolts, the CONTRACTOR shall map out the
reinforcement bars and links in the existing columns, beams or slab using electromagnetic
measurement methods. The EMPLOYER shall approve the method to be adopted.
The CONTRACTOR shall ensure that drilling of holes for anchor bolts in existing/new concrete shall

be done at locations where there are no reinforcement bars. If the CONTRACTOR encounters steel

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reinforcement bars, while drilling, he shall immediately cease the drilling operation and re-locate to
another drilling zone free from reinforcement bars. The aborted hole shall be covered up using high
strength non-shrink grout/mortar to the satisfaction of the EMPLOYER.
The CONTRACTOR shall engage a qualified and competent professional, subjected to the approval
of the EMPLOYER to design and detail anchor bolts or anchor bolt groups to withstand the most
critical forces inherent at the connection interface. Where design forces to be resisted at the
connection are clearly specified, design and detailing by the CONTRACTOR shall comply
accordingly.
Approved non-shrink cementitious grout of minimum compressive strength of 45N/mm2 shall be
used for bedding steel bases or bearing plates on concrete base.

3.7 FIREPROOFING PROTECTION

Generally, structural steel columns/beams/decking below the concrete columns supporting the steel
roof shall be fireproofed to give a fire resistance of at least two (2) hours; structural steel columns /
beams / decking on and below the first level shall be fireproofed to give a fire resistance of at least four
(4) hours.

The CONTRACTOR shall submit his fireproofing proposal for the EMPLOYER’s approval. Any
fireproofing proposal submitted must be approved for usage by the relevant authority. The proposed
fireproofing material must be compatible with and have strong adhesion to the corrosion protective
system specified.

3.8 Miscellaneous Structural Steel platform / skeleton / framing etc.

Structural steel platform/skeleton/framing etc. to be of the size, sectional shape and weight indicated
on or required by the drawings and includes all loose structural shapes, plates, bolts, rivets and other
pieces and fittings required to provide complete and substantial erection or installation to accommodate
the intended purposes and use. All hangers and anchors where shown to be made of Stainless steel,
shall have smooth finish.

Stair Well Railing

32 mm inside diameter mild steel pipe stair railing shall be provided at all outside stair strings, and
around stair well where and as indicated on drawings.

Stair and well railing to consist of a continuous top and intermediate pipe railings, supported on bent
plate brackets welded to plates, fixed with appropriate anchor bolts, as detailed on drawings. All railings
provided with continuous easements where stair runs change directions in all cases.

Miscellaneous Iron pipe railing

Where tubular iron pipe railings are req. for any exterior or interior building locations, furnish and install
a 38 mm (I.D) standard weight, mild steel pipe top and intermediate- railings, with pipe rail upright
stiffener standards as detailed on drawings. Ends of pipe rail at walls and uprights at floor to be provided
with standard type floor flanges for welding to pipe uprights secured in a positive and rigid manner, fixed
with appropriate anchor bolts to concrete slabs, platforms or curbs. All joints and connections in pipe
railing and upright standards shall be welded, without fittings and all welds ground smooth and corners
neatly rounded.

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Grating / Access door

Steel grating/door of approved design shall be provided wherever required. Gratings shall be of suitable
size to support a concentrated load of 230 kg @ center. Submit shop drawings for approval.

Protection screens (Vent opening in roof & elsewhere required)

Where vent stack shafts terminate at roof levels, furnish and install expanded metal gratings designed
to accommodate not less than 500 kg/m2. Gratings shall be mounted in angle frames welded at
intermittent points to provide necessary security to angle frame. Provide intermediate tee or angle
supports where necessary where spans exceed allowable deflections. Grating frames shall be anchored
to concrete curbs where required. All intake gratings to be provided with galvanized woven wire (No.
14 gauge) bird screens, clipped to gratings.

Ladder

a. Ladders for General Use

Ladders shall be provided where required by the drawings. Side rails shall be 63.5 mm x 12.5
mm steel flats, 500 mm apart and with 19 mm round rings 300 mm on centers, shouldered,
headed and welded to side bar frames. Anchor at top and bottom, and at intervals in between, not
exceeding 1.22m apart where such lengths exist in an approved manner so as to be permanently
secure. Erected so that all ladder rungs are 150 mm out from face of wall unless indicated
otherwise.

b. Step Iron for U.G. Tank

Step Iron shall be in two vertical runs at 225 mm centers horizontally and 300 mm centers vertically.
Top step iron shall be 450 mm below the manhole cover and the lowest not more than 300 mm
above the bottom level. Step iron shall be hot dipped galvanized or alternatively stainless steel.

3.9 Weld Tests and Inspection

3.9.1 Ultrasonic testing in accordance with BS 5996 and visual inspection in accordance with BS
4848 shall be utilized to verify base materials for laminations, inclusions or other
discontinuities where specifically noted. All high tensile steel plates Grade 50 and above shall
be tested for lamination.

3.9.2 Before undertaking the welding of any steelwork, the Contractor shall have obtained the
EMPLOYER approval for the electrodes and welding processes, and his welders shall have
been duly qualified for the work intended all as specified.

3.9.3 Welding tests using procedures and materials similar to those intended for production welding
shall be carried out by the Contractor as directed by the EMPLOYER and in the presence of
the Independent Inspection Agency and to their satisfaction. Each finished joint shall be
subjected to a radiographic test and/or ultrasonic tests and macro-examinations in addition to
two reduced section and guided bend tests, as specified in the relevant B.S.

3.9.4 The Contractor shall, at his own expense, provide all test pieces for the development of
welders’ tests/welding procedures and for the testing of welds, and shall include for the
dressing and surface preparation of weldments necessary for the appropriate weld inspection
and testing.

3.9.5 The Contractor shall provide run-off tabs and/or coupon plates at both ends of all butt welds.

The Contractor shall make sufficient allowance in his tender for any sizes of coupon plates as

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may be required by the Independent Inspection Agency.

3.9.6 The Contractor shall carry out the following tests at the workshop to ensure the quality of the
welds.

i. Weld measurements for at least 15% of all welds on a random basis.

ii. Magnetic particle tests (according to BS 6072) on 30% of all fillets welds

iii. Ultrasonic tests, examination level 2 (according to BS 3923, Part 1) on 50% of full
penetration butt wells.

iv. Radiographic tests on 15% of all splice butt welds.

3.9.7 The Contractor shall carry out the following tests at the works site:
i. Weld measurements for at least 15% of all welds on a random basis.

ii. Magnetic particle tests (according to BS 6072) on 60% of all fillets welds

iii. Ultrasonic tests, examination level 2 (according to BS 3923, Part 1) on 100% of full
penetration butt welds.

iv. Radiographic tests on 100% of all splice butt welds in tension in members of the primary
steel structure, and on 25% of splice welds in compression members.

3.9.8 These tests will generally be conducted in the following manner:

i. Radiographic or ultrasonic inspection or both shall be used when the overall soundness of
the weld cross section is to be evaluated.

ii. Magnetic-particle inspection shall be used when investigating the outer surface of welds or
as a check of intermediate weld passes such as root passes and of chipped, ground or gouged
joints prior to depositing subsequent passes.

iii. The final non-destructive testing shall be delayed to accommodate occurrence and detection
of delayed cracking.

iv. Where welds do not meet a standard to the satisfaction of the EMPLOYER, the defective
portion with the EMPLOYER permission may be removed and then re-welded for re-testing.

v. For every failure of the test results, the Contractor shall provide for 1 additional test the cost
of which shall be borne by the Contractor.

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