COMPLETE REVISION

September 2016

Structural

PIP STE01100
Constructability Design Guide
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has been
prepared from the technical requirements in the existing standards of major industrial users,
contractors, or standards organizations. By harmonizing these technical requirements into a
single set of Practices, administrative, application, and engineering costs to both the
purchaser and the manufacturer should be reduced. While this Practice is expected to
incorporate the majority of requirements of most users, individual applications may involve
requirements that will be appended to and take precedence over this Practice. Determinations
concerning fitness for purpose and particular matters or application of the Practice to
particular project or engineering situations should not be made solely on information
contained in these materials. The use of trade names from time to time should not be viewed
as an expression of preference but rather recognized as normal usage in the trade. Other
brands having the same specifications are equally correct and may be substituted for those
named. All Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines should
conflict with OSHA or other applicable laws or regulations, such laws or regulations must be
followed. Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at
Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member Companies and
Subscribers may copy this Practice for their internal use. Changes or modifications of any kind
are not permitted within any PIP Practice without the express written authorization of PIP.
Authorized Users may attach addenda or overlays to clearly indicate modifications or
exceptions to specific sections of PIP Practices. Authorized Users may provide their clients,
suppliers and contractors with copies of the Practice solely for Authorized Users’ purposes.
These purposes include but are not limited to the procurement process (e.g., as attachments to
requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and
issue of design engineering deliverables for use on a specific project by Authorized User’s
client. PIP’s copyright notices must be clearly indicated and unequivocally incorporated in
documents where an Authorized User desires to provide any third party with copies of the
Practice.

PUBLISHING HISTORY
December 2009 Issued
September 2016 Complete Revision

Not printed with State funds

 COMPLETE REVISION
September 2016

Structural

PIP STE01100
Constructability Design Guide
Table of Contents
1. Scope ............................................ 2 7. Architectural .............................. 18
7.1 Design Considerations .................... 18
2. References ................................... 2 7.2 Openings ......................................... 18
2.1 Industry Codes and Standards .......... 2 7.3 Coatings and Finishes ..................... 19
7.4 Scheduling ....................................... 19
3. Definitions .................................... 2 7.5 Coordination .................................... 19

4. General ......................................... 3 8. Revamp and Turnaround Work .. 19

4.1 Process Introduction .......................... 3 8.1 General ............................................ 19
4.2 Project Initiation and Development .... 3 8.2 Piling Considerations ....................... 19
4.3 Modularization ................................... 5 8.3 Field Verification .............................. 20
4.4 Pre-Assembly .................................... 5 8.4 Pre-Turnaround and
4.5 3D Models, Design Drawings and Post-Turnaround Work .................... 20
Contract Documents .......................... 5 8.5 Bolted Versus Welded
Connections ..................................... 20
5. Civil ............................................... 6 8.6 Temporary Supports ........................ 20
5.1 General Considerations ..................... 6 8.7 Site Work Considerations ................ 21
5.2 Geotechnical and Site Survey ........... 6 8.8 Work Packages ............................... 21
5.3 Excavation and Backfill ...................... 6
5.4 Grading and Roadways ..................... 8
5.5 Underground Piping and Utilities ....... 8
5.6 Sumps, Pits, and Manholes ............... 9

6. Structural ...................................... 9
6.1 Concrete ............................................ 9
6.2 Structural and Miscellaneous Steel . 15

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1. Scope
This Practice provides engineers and designers with guidelines for improving constructability of a
project.
This Practice describes guidelines for improving constructability of civil, structural, and
architectural components of a project. This Practice provides guidelines for grass root projects,
revamp projects, and turnarounds.

2. References
Applicable parts of the following PIP Practices, industry codes and standards, and government
regulations shall be considered an integral part of this Practice. The edition in effect on the date of
contract award shall be used, except as otherwise noted. Short titles are used herein where
appropriate.

2.1 Industry Codes and Standards

 Construction Industry Institute (CII)
– CII SP34-1 - Constructability Implementation Guide

3. Definitions
constructability: The optimum use of construction knowledge and experience in planning, design,
procurement, and field operations to achieve overall project objectives

contract documents: Any and all documents, including codes, studies, design drawings,
specifications, sketches, practices, and data sheets, that purchaser or engineer of record has
transmitted or otherwise communicated, either by incorporation or reference, and made part of
the legal contract agreement or purchase order between purchaser and constructor

conventional construction: A method of construction where individual elements and components

from multiple fabricators, vendors, and suppliers are shipped to the construction site and
assembled piece-by-piece into the final structure or building; sometimes referred to as “stick
built.” This traditional method of construction tends to concentrate craft labor hours in the field.

grass roots project: A project where construction is substantially performed in a clear, open site
with minimal interference from constructing around existing facilities

modularization: A method of construction where individual elements and components are

shipped to one or more module fabrication shops where they are assembled into complete units
that are shipped to the construction site for installation. This type of construction tends to move a
portion of craft labor hours from the field to a controlled shop environment.

owner: Party who has authority through ownership, lease, or other legal agreement over site,
facility, structure, or project wherein what is to be provided or installed will be used

pre-assembly: A process by which various materials, prefabricated components, and/or

equipment are joined together at a remote location for subsequent installation as a unit

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revamp project: A project (i.e., retrofit) that is substantially constructed in and around existing
facilities, typically containing significant modification to existing structures and plant equipment
and systems. Often, the project goal is to increase current product output or change the types of
products produced.

turnaround: Scheduled plant or unit outage when modification work is performed

4. General

4.1 Process Introduction

4.1.1 Constructability is a process driven by the desire to improve execution of the
construction phase, especially by considering construction issues during planning
and design phases, resulting in improved overall project delivery costs and
schedules. See CII SP34-1 for detailed implementation guidance.
4.1.2 The constructability process is implemented through a team effort involving the
owner project team, engineering contractor, and construction contractor
(including vendors, suppliers, and subcontractors if applicable) working towards
the common goal of producing a quality facility, while optimizing cost, schedule,
and safety.
4.1.3 Guidance provided in this Practice is generic with respect to project execution
strategy (i.e., principles should be applicable regardless of the contracting
strategy) provided that key project members participate in constructability
planning.
4.1.4 Construction site development shall include temporary facilities to support
project construction activities. It may involve one or more of the following items:
a. Temporary/permanent access ways
b. Temporary buildings, parking area and other facilities
c. Temporary site drainage and permits
d. Temporary power, communications and utilities
e. Temporary fencing, security and signage
f. Temporary wash down areas
g. Construction laydown areas and fabrication yards
h. Topographical survey

4.2 Project Initiation and Development

4.2.1 The life cycle of a typical process industry project matures from identification of
a need or business opportunity to an operating or producing facility through
several distinct phases or stages. Although most owners have their own uniquely
defined project development process, most projects progress through stepped
phases with similar traits. These project execution strategies are often
characterized by end-of-phase hold points (i.e., gates) when decisions are made
to continue funding or cancel a project based on successively refined total
installed cost estimates.

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4.2.2 Initial phases of a project typically involve appraisal of the business case for a
particular need or opportunity. These initial phases typically have limited civil,
structural, and architectural discipline involvement. A selection phase follows
where multiple options are narrowed to the one deemed most likely to achieve
business objectives. The selection phase often culminates in a process design
package with major process equipment needs identified and a plot plan proposed.
The next phase is called the project definition phase. This phase involves
preliminary engineering that defines a project to the point where the owner’s
review board may approve final funding for latter phases (i.e., detailed
engineering and construction). Attention to concepts of constructability should
begin no later than the end of the selection phase and incorporation of concepts
into the project should continue throughout the project’s duration.
4.2.3 Successful projects are typically achieved through good definition and detailed
planning. Plans for executing a project should address strategies for executing
engineering, procurement, and construction. Constructability planning can add
value to project execution through cost and schedule reductions.
4.2.4 Key constructability suggestions for consideration in early project front end
development are:
a. Engage construction team members as early as possible in project initiation
for development of the construction strategy.
b. Communication among team members is of paramount importance.
Encourage input on constructability from owner’s operations representative,
design engineer, construction representative, geotechnical consultant, etc.
c. Develop constructability checklists for use by the project team for each phase
of the project.
d. If land use for temporary facilities (e.g., construction field offices, site
fabrication yards, material storage and contractor parking) is required, seek
input from construction representative. Locate these items considering site
traffic patterns, access for trucks, and high risk areas (e.g., blast zones,
chemical exposure). Avoid relocating these items later in the project.
e. Decide on final plot plan/equipment arrangement. Include considerations for
permanent support facilities (e.g., warehouses, roads, crane access, parking
lots, and maintenance shops). Ensure construction sequencing cannot close
haul routes for heavy equipment because of height, width, length, and weight
restrictions. Obtain agreement from stakeholders to hold to plan.
f. Perform transportation studies to identify water or land routes, maximum
shipping weights, dimensional envelopes, and methods of transport.
g. Develop a strategy for site survey dimensional control that considers
different challenges that revamp or grass roots projects present.
h. Develop plans for addressing soil contamination, pollution control, erosion
control, wetlands preservation, storm water discharge, asbestos abatement,
disposal of hazardous waste, other environmental issues, and worker health
and safety. These plans need to be identified in project documentation and
drawings where applicable.

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i. Solicit owner and construction representative input on selection of materials

of construction.
j. Consider impact of likely weather and seasonal climate conditions on
construction activities when preparing schedules.

4.3 Modularization
4.3.1 Potential for modularizing structures, pipe racks, platforms, stair towers, roof
framing sections, electrical rooms, etc., should be reviewed at the beginning of
the selection phase. Other installations may be modularized at the steel
fabrication shop or on the jobsite before erection.
4.3.2 Modularization tends to decrease a project’s onsite construction schedule and
number of onsite craft workers. These potential benefits can add value to projects
located in geographical regions with climate extremes, craft labor resource
shortages, or high craft labor rates. However, these benefits may be offset by
additional design, material, transportation, and lifting costs.
4.3.3 Front end project planning, including transportation studies, becomes critical
with any significant degree of modularization. It is often necessary to accelerate
detailed design schedules, including vendor documentation, to accommodate
modular shop schedules and material required-at-shop dates.
4.3.4 Construction crane size requirements for modules are typically increased and
large cranes may need to be scheduled much longer in advance because of their
specialized nature.

4.4 Pre-Assembly
4.4.1 If modularization is not used, construction representatives should still participate
in conceptual planning of structures, pipe racks, and bridges to provide input into
practicality of pre-assembly and erection techniques.
4.4.2 Some of the schedule and field labor benefits of modularization can still be
realized by incorporating pre-assembly concepts. Fewer large components can be
erected versus conventional construction piece-by-piece methods. Pre-assembly
can be performed onsite or coordinated with fabricators. The concept of pre-
assembly can be extended to pre-cast concrete components.

4.5 3D Models, Design Drawings and Contract Documents

4.5.1 Consider using computerized 3D models for improved constructability,
operability, and maintainability of plant designs.
4.5.2 References to codes should be minimized on drawings, except drawings for
general notes. If necessary to reference codes on drawings, be specific by citing
the code, page, paragraph, section, etc.
4.5.3 Where discipline interfaces occur (e.g., Civil, Mechanical, Electrical, etc.),
drawings should be cross referenced between disciplines. Appropriate cross
references can save more hours in the field than those required to incorporate
references on drawings.

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4.5.4 For revamp projects, cross references to relevant existing drawings should be
shown on new construction drawings. Include copies of relevant existing
drawings in the contract documents.
4.5.5 All plan drawings for each discipline should use the same orientation, grid and
scale, if possible.
4.5.6 For locating equipment and facilities, all disciplines should use consistent
reference points for dimensioning.
4.5.7 Contract documents should clearly specify procurement responsibilities for
contractor provided material.

5. Civil

5.1 General Considerations

5.1.1 Fence plans and details should be developed early in the detailed engineering
phase to aid with security measures.
5.1.2 Design of all foundations, manholes, sumps, underground piping, and site
improvement plans including rough grading, drainage, and roadways should be
completed early in the detailed engineering phase of the project.
5.1.3 Design and installation of underground facilities should be coordinated to avoid
interferences and rework.
5.1.4 Design and installation of heavy haul roads, roll on/roll off ramps, bulk materials
handling, and other logistics facilities should be completed early in the project to
ensure they are available when required.

5.2 Geotechnical and Site Survey

5.2.1 Geotechnical and topographic surveys should be obtained early in project
definition phase.
5.2.2 Obtain location surveys of existing facilities, particularly underground facilities.
Consider laser scanning of existing equipment and structures.
5.2.3 Survey control monuments should be established so that monuments remain
accessible and undisturbed for the duration of the project.
5.2.4 The need for a soil structural assessment for heavy load requirements should be
determined.
5.2.5 Construction input should be obtained for establishment of benchmarks and/or
reference points to be used during construction.
5.2.6 A copy of the geotechnical report should be furnished to the civil contractor.

5.3 Excavation and Backfill

5.3.1 If possible, excavations below the water table should be avoided. Alternate
foundation schemes should be investigated.
5.3.2 Appropriate requirements for backfill compaction and maximum lifts for traffic
versus non-traffic areas should be specified.

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5.3.3 Geotextile fabric, geogrid, granular material, mud mats or lean concrete should
be used in the bottom of excavations as appropriate.
5.3.4 If possible, use of sheet piling for temporary shoring should be avoided. Trench
boxes are preferred for shallow excavations.
5.3.5 Regulatory (e.g., OSHA) shoring requirements for excavations for foundation
and underground utility designs should be incorporated. To eliminate excessive
shoring, deep cuts should be avoided.
5.3.6 Minimum elevations for excavation should be established. Mass excavate if
possible.
5.3.7 Foundations in congested areas should be designed with bottom of concrete at
same elevation if possible. Mass excavation (e.g., bathtub) design concepts
should be used.
5.3.8 Depth of excavations for foundations, including any mud slabs, aggregate beds,
etc., should be limited to 4 feet (1200 mm) maximum if consistent with
geotechnical engineer's recommendations in order to minimize requirements for
confined space, sloped back excavations, or shoring.
5.3.9 Unless the area has a potential for re-excavation, use of Controlled Low-Strength
Material (CLSM) or flowable fill to backfill around foundations in confined or
congested areas should be considered.
5.3.10 Use of a lightweight aggregate backfill for retaining walls should be considered if
the reduction of backfill unit weight and reduced active wall pressure provide an
economical alternative to a cohesionless soil backfill.
5.3.11 Studies should be performed to determine if contaminated soils are present, and
plans should be included in contract documents to address contaminated soil
handling issues (e.g., personnel exposure, equipment exposure, wash down, etc.).
5.3.12 If contaminated soil exists at the site, a plan for disposal of the soil should be
developed.
5.3.13 Rather than including contaminated soil location and removal in typical
construction contracts, owners may decide to separately handle the risk of
locating and disposing of the soil, which can be more cost effective. A specialty
contractor with appropriate equipment and properly trained staff may be
employed ahead of the main construction contract to mitigate and/or advise on
methods to minimize disposal of contaminated soil.
5.3.14 Depending on the consequences of finding contaminated soil, a radical
re-design of the work (e.g., building a unit above existing grade to avoid
excavation of potentially contaminated soil) may be considered necessary.
5.3.15 If soils are to be hauled off-site, a plan should be developed to minimize
additional handling and to avoid any delays associated with trucking.
5.3.16 Dewatering issues for soil excavations should be addressed. If contaminated soils
are present, typically contaminated groundwater is also present. Locations for
power for dewatering pumps, groundwater storage, and groundwater discharge
should be identified during the design phase of the project.

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5.3.17 Along with the site plan, a general grading plan should be developed that
addresses rough and final grading issues and any heavy lift site preparation
requirements. Requirements for transporting heavy equipment to the site
(e.g., heavy haul roads, etc.) and off-loading should be developed.
5.3.18 Care should be taken to not undermine existing foundations or utilities. If
undermining cannot be avoided, temporary support requirements should be
addressed during the design phase and included on excavation drawings.
5.3.19 Site layout should be arranged for maximum use of mobile or self-propelled
compaction equipment.

5.4 Grading and Roadways

5.4.1 During the construction phase, site water runoff disposal should be provided.
5.4.2 If possible, cut and fill should be balanced. Provide stockpile areas to avoid
moving excavated material multiple times.
5.4.3 Erosion control requirements should be determined in accordance with regulatory
requirements and local codes.
5.4.4 Available locations for construction water access for site earth work and dust
control should be determined.
5.4.5 If possible, permanent roads and drainage should be used to provide good access
and mobility during construction.
5.4.6 If parking areas are being relocated, reusing base course materials and asphalt
should be considered.
5.4.7 Plot elevation should be raised and sloped to facilitate drainage during the
construction phase and for the permanent facility. Use of temporary ditching
during the construction phase should also be considered.

5.5 Underground Piping and Utilities

5.5.1 Typical sections on detail drawings should be provided to show requirements for
bedding materials for underground utilities.
5.5.2 A culvert schedule should be developed. If heavy loading or roadway loading
occurs at a culvert location, the loading should be considered in underground
piping design.
5.5.3 Underground utility corridors should be located in areas that cannot interfere
with construction of deep foundations.
5.5.4 If possible, common excavation trenches should be used for underground piping,
direct buried cable, and duct banks.
5.5.5 Developing a composite drawing of all temporary, new, and existing
underground installations (i.e., foundations, piping, and electrical) should be
considered.
5.5.6 If leak detection and secondary containment of process sewers and piping is
required, trenches should be considered.

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5.5.7 Underground piping, grounding, duct banks, and ductwork should be designed
early enough to permit installation during the site work and foundation
installation phase.
5.5.8 Corrugated arch pipe, precast elliptical pipe, or precast box culverts should be
considered for use at road crossings rather than cast-in-place box culverts.
5.5.9 Existing underground utilities should be located and shown on underground
piping drawings and foundation location plans.

5.6 Sumps, Pits, and Manholes

5.6.1 If facility standards permit, precast manholes, sumps, and electrical pull boxes
should be used if possible.
5.6.2 Details for valve boxes, small sumps, and manholes should incorporate
reinforced concrete pipe (RCP) if possible. Details should avoid cutting of RCP
if practical.
5.6.3 Sumps or pits with interior lining (e.g., for acid proofing) should have a plastic
barrier installed under the bottom slab and walls should be externally coated with
a waterproofing material, before backfill, to prevent seepage through cracks
caused by concrete shrinkage. Seepage can impair installation of interior coating.
5.6.4 For pits with vertical concrete walls, use of fabricated ladders should be
considered rather than cast-in-place rungs.
5.6.5 Manhole frames and covers can have long lead times and should be ordered in
time to accommodate construction schedule.
5.6.6 Precast manholes should be provided with means for lifting.

6. Structural

6.1 Concrete
6.1.1 Foundations
6.1.1.1 Small pump foundations and other lightly loaded piers and pads should
be placed on a thickened slab rather than on deeper foundations requiring
more excavation.
6.1.1.2 If placing walls on a slab, slab dimensions should be extended to permit
setting outside forms for walls on the slab.
6.1.1.3 If structural and site conditions permit, foundations should be designed
to permit placement of concrete directly against face of earth, thus
eliminating need for forms.
6.1.1.4 For positioning large vertical vessels during equipment setting, the
length, threads, and projection of one anchor should be greater than the
rest in the group.
6.1.1.5 For small foundations and slabs-on-grade, full depth foundations without
edge grade beams should be considered.

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6.1.1.6 Use of standard diameter concrete piers rather than square and
rectangular shapes should be considered for ease of forming.
6.1.1.7 If varying the surfaces or sections of concrete, the additional form costs
should be considered. Haunches and other labor intensive forming should
be avoided.
6.1.1.8 For supporting vertical vessels, pedestals 6 feet (1800 mm) and greater in
diameter should be octagonal or round in shape. Smaller pedestals should
be square, or round if forms are available.
6.1.1.9 Foundation sizes for pumps, piperacks, structures, and miscellaneous
supports should be standardized as practical.
6.1.1.10 Foundation dimensions should be designed in increments that allow for
maximum use of commercial form sizes. Use re-useable forms where
possible to reduce cost. Disposable forms are often more costly.
6.1.1.11 Use of Concrete Maturity Method should be considered for testing
concrete rather than conventional cylinders.
6.1.1.12 Combining footings for structural columns that are located in close
proximity to one another should be considered. Equipment foundations
and structural columns should be combined on a common mat in
congested areas.
6.1.1.13 Concrete column dimensions should remain the same from floor to
floor.
6.1.1.14 Straight walls should be used rather than battered walls. Savings in form
work for straight walls can offset the cost of additional material.
6.1.1.15 Increasing column sizes to facilitate placement and consolidation of
concrete should be considered. If columns/piers are greater than 6 feet
(1800 mm) high, a minimum of 6 inches (150 mm) clear space should
be provided through column reinforcement for concrete placement.
6.1.1.16 Where piers need to be omitted for crane access, use of dowel bar splice
kits on large diameter reinforcing should be considered.
6.1.1.17 Use of key ways in wall joints should be minimized. To eliminate key
ways, steel reinforcement in joints should be designed for shear friction.
6.1.1.18 The construction representative should be consulted regarding complex
concrete placements (e.g., tabletops). Forming hardware, shoring
methods, joints, and special embedded items can impact design.
6.1.1.19 For deep wall foundations, use of sheet piling or soldier pile and lagging
systems as permanent, external forms should be considered.
6.1.1.20 Foundation requirements for any heavy lifting equipment should be
considered.
6.1.1.21 Local availability of concrete aggregates, cements, pozzolans, and
admixtures for special mix designs should be investigated.

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6.1.1.22 If possible, foundations (depth and proximity) should be located and

designed to prevent undermining adjacent foundations, manholes,
sumps, etc. Use of shoring should be minimized.
6.1.1.23 For buildings, embedded floor channel for supporting switchgear should
be installed flush and level with top of floor to permit easy installation
and removal of switchgear.
6.1.1.24 Conduit and piping stub-outs and penetrations should be shown on
foundation drawings and other appropriate discipline drawings should
be referenced.
6.1.2 Piles and Drilled Piers
6.1.2.1 Advantages and disadvantages of different types of deep foundations
(e.g., caissons, H-piles, pipe, auger flight, augered cast-in-place or
precast concrete piles) should be investigated. Avoid underream or bell
bottom footings if possible.
6.1.2.2 Use of test piling should be considered to maximize economy in design
of production piling.
6.1.2.3 Where vibration effects on nearby facilities can be detrimental, drilled
piles (e.g., augered cast-in-place, slurry/casing drilled piers or mini piles)
rather than driven piles should be used.
6.1.2.4 Multiple mobilizations for piling contractors should be avoided.
6.1.2.5 For individual columns in offsite areas, drilled piers rather than spread
footing foundations should be considered.
6.1.2.6 For drilled piers which employ casing for hole stability, hooked
reinforcing should not be permitted to extend past the casing in order to
avoid interferences when extracting the casing.
6.1.2.7 To facilitate placement of concrete and anchors, a construction joint
below the bottom of anchors should be considered.
6.1.2.8 Where drilled piers or augered cast-in-place piles are used, pier/pile
installation must be staggered in spacing or timing to provide sufficient
room for accessibility for cranes and/or other equipment and allow for
sufficient concrete/grout set time.
6.1.2.9 Drilled piers or piles which can support heavier loads on a wider spacing
interval should be considered.
6.1.3 Pre-cast Concrete
6.1.3.1 Use of pre-cast manholes, pull boxes, sumps, retaining walls, and other
miscellaneous concrete items should be maximized. Pre-casting small
spread footings should be considered.
6.1.3.2 If cost or schedule savings are possible, concrete structures should be
designed for pre-cast construction.
6.1.3.3 Pre-cast concrete trenches should be considered for roadway utility
crossings and process applications. If containment is critical, special care
should be given to joint design.

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6.1.3.4 Deliveries of pre-cast concrete items should be coordinated to allow

items to be off loaded in final locations to avoid multiple handling.
6.1.4 Reinforcement
6.1.4.1 Unless different grades of rebar are required by codes or special
applications (e.g., seismic and blast ductility, epoxy coatings for
corrosion, and cryogenic environments), use of various grades of rebar
should be avoided.
6.1.4.2 Congestion of reinforcing steel, ties, and anchors in cross section should
be reduced using the following design concepts to facilitate concrete
placement:
a. Use fewer reinforcing bars of larger diameter, rather than more
reinforcing bars of smaller diameter.
b. Arrange ties within cross sections to provide maximum clearance
between bars.
c. If permitted by code, use ties with 90 degree hooks rather than closed
ties.
d. Consider use of mechanical couplings in congested areas rather than
lap splices.
6.1.4.3 Welded wire reinforcement or fiber reinforced concrete should be
considered for area paving rather than rebar. Flat sheet welded wire
reinforcement should be used rather than rolled welded wire
reinforcement.
6.1.4.4 Consider using consistent beam sizes and rebar sizes throughout the
structure.
6.1.4.5 Show rebar, post-tensioning cables, and conduits on one overall design
drawing in order to detect interferences before construction.
6.1.4.6 Consider using rebar in foundations for grounding.
6.1.5 Roadways and Area Paving
6.1.5.1 The construction representative should be consulted to define areas
where early construction of roadways and area paving would be
beneficial.
6.1.5.2 Area paving drawings should be developed that show locations of
contraction and expansion joints.
6.1.5.3 For contraction or construction joints in large area paving, use of metal
screed keys with removable strips should be considered.
6.1.5.4 Curb heights should be specified to facilitate forming with standard
dimensional lumber unless a paving machine is being used.
6.1.5.5 For roadways and area paving, consider thicker section and/or fiber
reinforcement to eliminate steel reinforcement.

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6.1.6 Concrete Mixing

6.1.6.1 For large concrete placements or special mix designs, a preplanning
meeting should be held with concrete suppliers and contractors.
6.1.6.2 Requirements for an on-site batch plant versus a local concrete supplier
should be determined in the project definition phase. Allowance for
additional inspections, if required, should be included in the project
schedule.
6.1.6.3 If practical, a common concrete compressive strength should be used.
Unique mix identifiers should be shown on delivery tickets.
6.1.7 Anchors and Embeds
6.1.7.1 If practical, anchors should be standardized as follows:
a. Specify consistent material, length, and thread requirements.
b. Minimize use of different diameters and anchor lengths.
c. Use minimum increments of 1/4 inch (6mm) if different diameters
are required.
d. Specify plate and nut or end nut rather than J-Hook anchors.
6.1.7.2 Cast-in-place anchors should typically be considered as follows:
a. For anchors 3/4 inch (19 mm) or larger in diameter
b. For anchoring major equipment or structures
c. Use templates rather than sleeves if precise alignment is required for
anchors greater than 1 inch (25 mm).
d. Use sleeves if pre-tensioning is required.
6.1.7.3 Post-installed bonded anchor systems should be considered as follows:
a. For anchors 3/4 inch (19 mm) or smaller in diameter
b. For larger anchors where constructability issues noted below are
encountered:
1. For anchoring equipment to existing concrete
2. If securing the anchors in required location is difficult before
concrete placement
3. If pre-installed anchors can interfere with equipment setting,
concrete placement, or finishing
6.1.7.4 Post-installed mechanical anchor systems should be considered as
follows:
a. If recommended by equipment supplier
b. Typically for anchors 7/8 inch (22 mm) or smaller
c. Especially suitable for overhead anchoring
d. Generally not recommended for dynamic load applications

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6.1.7.5 Special anchor requirements (e.g., alloy steel, high-strength, or hot-

dipped galvanizing) should be determined early in detailed engineering
phase.
6.1.7.6 Adequate embeds should be provided in concrete surfaces for
miscellaneous attachments.
6.1.7.7 If possible, embedded items should be designed to be flush with concrete
for ease of forming. If required, the remainder of the embedded item
should be welded on later.
6.1.7.8 Where dense rebar is located in foundations, clearances for anchors or
embedded items should be checked.
6.1.7.9 If projecting anchors can interfere with construction or maintenance
activities, use of coupled type anchorage should be considered.
6.1.7.10 If jacking screws are not provided and pre-tensioning is not required for
lightly loaded equipment skids, leveling nuts should be added to
anchors rather than using shims.
6.1.7.11 Cast-in-place anchors should be designed in a square rather than
rectangular arrangement. Anchors placed in a rectangular arrangement
are often oriented incorrectly during construction.
6.1.7.12 If design considerations permit, anchors should not be extended into
footings (mats).
6.1.8 Grout
6.1.8.1 Weep holes should be provided for piers with grout pockets to permit
water to escape.
6.1.8.2 Vent holes should be provided in column or equipment base plates to
permit air to escape during grout placement.
6.1.8.3 Responsibilities for installing grout (e.g., surface preparation, equipment
positioning) should be clearly specified.
6.1.8.4 Grout thickness for structural steel and equipment support should be
specified between 1 inch and 2 inches (25 mm and 50 mm).
6.1.8.5 Grouting of equipment that is not sensitive to alignment or vibration
(e.g., transformers, tanks, minor supports, packaged buildings and
enclosures) should be avoided.
6.1.9 Grade Slabs and Elevated Slabs
6.1.9.1 Construction floor loadings for grade slabs and elevated slabs should be
established during the design phase to permit use of construction
equipment for placement of equipment, pipe, trays, ducts, etc.
6.1.9.2 Drawings that show locations of expansion joints should be developed.
Where standard spacing rules are not adequate, the location of control
joints should also be shown on drawings. Type of joints to be used
should be clearly specified.

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6.1.9.3 Elevated slabs drawings should show all penetrations by location and
size.
6.1.9.4 If practical, a uniform thickness for elevated slabs should be maintained
to minimize field labor costs.
6.1.9.5 Fiber reinforcing and/or thicker sections should be considered for lightly
loaded slabs to eliminate steel reinforcement.
6.1.9.6 A vapor barrier should be installed under grade slabs to minimize vapor
penetration for any interior floor slabs and where coatings or flooring
will be applied.
6.1.9.7 For slabs requiring coatings, surface finish should not be specified other
than what is required for flatness and levelness as finish will be removed
before adding coatings.
6.1.9.8 Avoid using curing compounds on concrete requiring protective
coatings.
6.1.9.9 Avoid scheduling outdoor coating installations during wet/cold
conditions.

6.2 Structural and Miscellaneous Steel

6.2.1 Connections
6.2.1.1 Use of through-web beam connections should be avoided. If this type of
connection is required, seat angles should be placed on columns.
6.2.1.2 If possible, boxed-in connections should be avoided where corrosion
cannot be easily prevented or corrected.
6.2.1.3 Field-welded connections should be minimized.
6.2.1.4 If pipe racks are designed for future expansion, columns should be
extended above top level to permit column splice connections.
6.2.1.5 Contract documents should clearly specify responsibilities for providing
connection materials (e.g., shim plates, bolt and nut assemblies, and
Direct Tension Indicator (DTI) washers).
6.2.1.6 Special care should be used when detailing moment connections.
Column stiffeners and doubler plates should be avoided where possible.
Where stiffeners are required, connection of beams framing into column
web needs to be considered.
6.2.1.7 Avoid full-depth stiffeners where possible.
6.2.1.8 Existing structures can require special connection designs to
accommodate fit-up and constructability due to dimensional
inconsistencies, misalignment, and existing members that are not level
and plumb.
6.2.2 Stairs, Ladders and Platforms
6.2.2.1 Permanent stairways, platforms, and ladders should be designed and
erected as soon as practical.

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6.2.2.2 As much as possible, ladders, stairways, catwalks, and miscellaneous

platforms should be pre-assembled in the shop.
6.2.2.3 Field cutting and banding of grating or floor plate penetrations should be
minimized.
6.2.2.4 For grating or floor plate fastening systems, constructor should be asked
to provide a preference and erection costs should be considered. Layouts
for grating penetrations should be suitable for supporting splits in grating
panels.
6.2.2.5 Stair stringers, treads, grating clips, and railing should be shipped with
related structural steel to allow erection with sequential access to
elevated tiers.
6.2.3 Fireproofing
6.2.3.1 If possible, use of shop-applied fireproofing should be maximized.
6.2.3.2 Impact of the weight of fireproofing on transportation and erection costs
should be considered.
6.2.3.3 Cost and schedule impacts due to repair of fireproofing damaged during
transportation and handling should be considered when selecting type of
fireproofing.
6.2.3.4 Erection clearances should be considered when determining block-out
dimensions for shop applied-fireproofing.
6.2.4 Fabrication
6.2.4.1 The construction representative should be consulted for establishing
delivery sequence of fabricated steel.
6.2.4.2 Miscellaneous steelwork items (e.g., equipment frames, architectural
items, grounding clips, etc.) that are not shown on structural drawings
should be checked to ensure these items are included in scope of
supplier, contract packages or purchase orders.
6.2.4.3 Field fabrication should be considered for miscellaneous supports
identified late in detailed engineering phase.
6.2.4.4 If coatings are used, quality control measures should be implemented to
prevent excessive build-up that can block placement of bolts in standard
holes.
6.2.5 Design of Structures
6.2.5.1 If possible, structure bay dimensions should be standardized.
6.2.5.2 Consider construction, operation, and maintenance access in locating
bracing at ground level.
6.2.5.3 Minimizing use of bracing and small members that are labor intensive to
install should be considered.
6.2.5.4 Pipe bridge clearances should be reviewed with construction,
maintenance, and operations personnel to verify access for large
equipment/oversized loads.

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6.2.5.5 If possible, use of different member sizes should be minimized, and

special or hard to fabricate shapes should be avoided.
6.2.5.6 Specifications, dimensions, and field connections should be standardized.
6.2.5.7 During the conceptual planning of all structures, pipe racks, and bridges,
the construction representative should provide input into the practicality
of pre-assembly and erection techniques.
6.2.5.8 Fabricated piece marked members should be duplicated for use in as
many suitable locations as possible.
6.2.5.9 Where fall protection is required, strategically placed and properly
designed means should be provided for supporting construction safety
cables.
6.2.5.10 Erection clearances for beams framed between existing beams and
columns should be verified. Allowances for horizontal alignment with
connections should be provided by using horizontal slots and/or field
welding.
6.2.5.11 If new equipment is to be installed in existing structures, the capacity of
overhead framing should be checked to ensure the framing can support
rigging for the new equipment.
6.2.5.12 Use of prefabricated L-shaped bent steel plates installed with the
structural steel should be considered to eliminate field forming for
exposed perimeter edges of elevated floor slabs.
6.2.5.13 Shear keys at column bases should be used only where required.
6.2.5.14 Special temporary steel required for erection should be identified and
provided with the fabricated steel.
6.2.5.15 Unless other arrangements are made with the construction contractor,
steel drawings issued for field fabrication should be complete with all
necessary fabrication details and bills of material. Notes should be clear
on which items are to be field fabricated.
6.2.5.16 Elevated slabs should be designed with galvanized decking (i.e., “Q”
decking) rather than forming. Structural steel beams should be designed
to support the deck loads without shoring.
6.2.5.17 Temporary guardrails should be avoided by designing permanent
guardrails to be attached to supporting steel.
6.2.6 Marking and Identification
6.2.6.1 Marking and tagging method should be legible after final finish coating
is applied.
6.2.6.2 Piece marks should be placed in a location consistent with member
orientation.
6.2.6.3 If tagging is to be obscured by fireproofing or other membrane, the piece
mark should be transferred to the exterior of membrane in the same
relative orientation.

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6.2.6.4 Receiving process should include verification of materials received

against the shipping papers.
6.2.6.5 Pieces should have the weight shown on the bill of lading and on shop
detail drawings so that suitable lifting equipment can be selected.
6.2.6.6 Fasteners for a shop order should be delivered before or with the first
delivery, and should be accompanied with a packing list giving proper
identification as to use. A bolt list and splice plate list should be provided
by fabricator. Bolts should be shipped in weather resistant containers.
6.2.7 Bolting
6.2.7.1 If possible, bolt diameters and assemblies should be standardized to
minimize errors and complexities in the field.
6.2.7.2 A simple procedure for meeting bolt tensioning requirements should be
provided that can be used by erector and inspector.

7. Architectural

7.1 Design Considerations

7.1.1 Architectural items (e.g., door hardware and fixtures) should be standardized.
7.1.2 Electrical and construction representatives should be consulted regarding
substation floor design (e.g., embedded channels).
7.1.3 Elevation of computer floors (if applicable) should be adequate to permit cable
run tie-ins to equipment.

7.2 Openings
7.2.1 Schedules and specifications for doors, windows, and hardware should be
developed early to facilitate ordering.
7.2.2 Structural, HVAC, piping, and electrical penetration details should be
coordinated with modular aspects of unit masonry.
7.2.3 Access requirements for process, electrical, and other equipment that is oversized
should be identified early in the detailed engineering phase.
7.2.4 Future expansion requirements should be considered during design of structures.
For fireproofed rooms and walls, kits should be used for wall penetrations of
cables and piping; and access panels and doorways for removal and replacement
of equipment.
7.2.5 Layout and details of all utility floor, roof and wall penetrations should be
developed and shown on civil/architectural drawings.
7.2.6 Block-out requirements should be reviewed to ensure correct location for
electrical bus duct locations.
7.2.7 If designing for blast effects, blast dampers, and doors should be specified early
to facilitate ordering.

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7.3 Coatings and Finishes

7.3.1 Architectural painting systems for structural, architectural, equipment, and piping
should be standardized.
7.3.2 Finishes for acoustical ceilings, wall coverings, painting, vinyl, and ceramic tile
should be standardized.
7.3.3 Special coatings that require application before installation of equipment should
be identified.

7.4 Scheduling
7.4.1 HVAC & fire detection are typically critical path systems that should be
completed early enough to permit installation and testing of control equipment.
7.4.2 Design methods should be considered that permit installation of equipment room
walls after placement of large equipment.

7.5 Coordination
7.5.1 Scope and interface definition for electrical, instrumentation, piping, and
mechanical equipment should be clearly specified in subcontract packages for
buildings.
7.5.2 Structural representative should be consulted regarding having structural steel
fabricator provide miscellaneous items (e.g., frames for louvers, vents, HVAC
supports, clips, etc.) that are shown on architectural drawings.

8. Revamp and Turnaround Work

8.1 General
8.1.1 This section provides additional constructability guidelines for revamp and
turnaround work. These guidelines should be considered in addition to those
found in other sections of this Practice.
8.1.2 Most of the items in this section are applicable to both revamp work in an
operating facility and turnaround work in a shutdown facility. Turnaround work
typically requires a more detailed (i.e., hour by hour) plan, whereas consideration
of specific safety issues may be an issue working in an operating plant.

8.2 Piling Considerations

8.2.1 Obstructions for accessibility (i.e., vertical and horizontal clearances) for pile
driving/drilling equipment for new piles/shafts should be considered. Low
headroom piling equipment and additional design may be considered where
clearances are limited.
8.2.2 Whether driving piles is permitted in the construction area near the facility
should be determined. Non-displacement piles (e.g., augered cast-in-place piles)
may be required to minimize transmitting vibrations to nearby operating
equipment.

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8.3 Field Verification

8.3.1 Locations of existing obstructions should be field verified to confirm that new
steel and foundations can be installed as designed without interferences. Existing
obstructions require field verifications because they may not be shown correctly
on existing drawings compared to the as-built condition.
8.3.2 Access requirements for operations and maintenance should be field verified in
order to avoid interference with new facilities being constructed.

8.4 Pre-Turnaround and Post-Turnaround Work

8.4.1 Part of the detailed planning process for turnarounds should include determining
what work can be completed pre-turnaround (i.e., while the facility is still
operating) and what work can be completed post-turnaround (i.e., after the
facility is started up again) in order to minimize the work required to be
completed during the turnaround.
8.4.2 Pre-turnaround preparation work should be completed to the greatest extent
possible to limit production down time. All work involved in the turnaround
should be sequenced to limit schedule impacts and minimize downtime.

8.5 Bolted Versus Welded Connections

8.5.1 Because facilities typically have restrictions on field welded connections during
normal operation, drilled and bolted connections may be required.
8.5.2 Typically, welding is not prohibited during a turnaround.
8.5.3 Bolted connections may require special considerations (e.g., existing fireproofed
members require fireproofing to be removed on both sides of joint).
8.5.4 Field bolted connections of structural steel are typically more economical than
field welded connections. Bolted connections do not require hot work permits,
x-ray or other inspection procedures required for welded connections.
8.5.5 For extensive field fabrication, multi-spindled drilling machines can be used to
provide accurate hole location and efficiency.
8.5.6 If a completely non-slip or water tight connection is required, welding may be
preferred.
8.5.7 Availability of qualified welders should be considered before field fabrication
begins.

8.6 Temporary Supports

8.6.1 Temporary support of existing piping, electrical, and structural steel during
demolition and construction should be considered; and who will be responsible
for this work should be determined.
8.6.2 If structural steel is to be demolished, using the steel to create temporary supports
should be considered.

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8.7 Site Work Considerations

8.7.1 The following items are often excluded from demolition and construction work
descriptions and may require a specialty contractor and permits to complete the
work:
a. Asbestos materials and mastics
b. Lead based paints or other hazardous materials
c. Siding on existing buildings
d. Heavy machinery/equipment transportation and operations
8.7.2 Safety in revamp projects might require the addition of a new work task to ensure
that existing equipment and facilities including pipelines, electrical and
instrumentation cables are protected against damage to prevent major setbacks or
even catastrophic events during the construction phase of the projects.
8.7.3 All site specific safe practices (e.g., Job Safety Analysis, Hot Work, Lift Plans,
Lockout/Tagout, Personal Protective Equipment, etc.) should be considered in
the work plan.
8.7.4 All craft workers should be familiar with Safety Data Sheets (SDSs) for issues
concerning their work areas.

8.8 Work Packages

8.8.1 Complete work packages for every individual portion of the work should be
developed. Work packages should include complete information on materials and
their sources and a detailed method statement of the work.
8.8.2 All planning and research should be completed and everyone involved should
have a complete understanding of the work to be performed.
8.8.3 Work packages should be descriptive enough to permit breaking up the package
as required to manage the work.
8.9 All stored job materials should be organized, identified, and verified before beginning
any work.
8.10 Smaller components should be pre-assembled into units as large as are manageable
before going to the field for the turnaround.
8.11 All anchorage layouts should be verified to ensure proper installation.
8.12 Space requirements for pre-positioning construction equipment and materials before
beginning turnaround work should be considered. Space requirements for rolling stock,
bottled gas requirements, scaffolding, and test equipment should be considered.
8.13 During the planning process, siting of temporary contractor facilities and requirements
for emergency egress and evacuation should be considered.
8.14 To ensure proper sequencing of the work, sequential completion of the work, and
subsequent turnover of the facility, all parties should agree to the turnaround detailed
schedule.

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8.15 Consideration should be given to the critical relationship between adjacent equipment
items or column lines for revamp work that may require locating all the work in an area
based on dimensions from an existing item.
8.16 Additional surveys, photography and laser mapping should be considered.
8.17 All design disciplines should reference the same benchmarks. Typically, different
benchmarks around an existing facility are not tied together properly. If some work is
designed with conflicting benchmarks, or if the work is engineered with one benchmark
and constructed with another, fit-up issues can occur.
8.18 In some cases a more complicated, lengthy revamp procedure performed before a
turnaround can be more economical than a simple demolition and replacement. For
example, dowelling into and modifying foundations of existing equipment may be more
economical than replacing a foundation during the turnaround.
8.19 Civil, structural, and architectural construction work should be coordinated with that of
other construction groups and engineering organizations. In conjunction with revamp
work, simultaneous construction of unrelated work by others can occur. Physically
marking the spots where items are to be constructed and communicating the plans to
owner’s area supervisor should be considered.

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