Project Quality Plan

STEEL STRUCTURAL
FABRICATION and ERECTION

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 Project Quality Plan

Table Of Content

1. PROJECT DESCRIPTION ........................................................................................................ 3

2. PROJECT QUALITY PLAN REVIEW AND APPROVAL ........................................................... 3
3. ORGANIZATION QUALITY POLICY ......................................................................................... 3
4. PROJECT QUALITY OBJECTIVES .......................................................................................... 4
5. PROJECT SCOPE .................................................................................................................... 4
6. DEFINITIONS ............................................................................................................................ 4
7. INSPECTION TEST PLAN (ITP) ............................................................................................... 5
8. SPECIFICATION AND STANDARDS ....................................................................................... 5
9. ROLE AND RESPONSIBILITIES ............................................................................................... 6
10. QUALITY ASSURANCE MANAGEMENT .................................................................................. 9
11. PREPARATION FOR FABRICATION ...................................................................................... 12
12. FABRICATION PROCESS ...................................................................................................... 14
13. DIMENSIONAL INSPECTION ................................................................................................. 19
14. SURFACE FINISHING INSPECTION ...................................................................................... 19
15. CONTROL OF NON-CONFORMANCE PRODUCT ................................................................ 20
16. FINAL INSPECTION ................................................................................................................ 20
17. DELIVERY TO SITE ................................................................................................................ 21
18. RECEIVING OF FABRICATION MATERIAL ........................................................................... 21
19. PREPARATION FOR ERECTION ........................................................................................... 21
20. ANCHOR BOLT INSTALLATION............................................................................................. 22
21. ALIGNMENT OF STEEL STRUCTURAL WORK ..................................................................... 22
22. BOLT TIGHTENING ON STEEL STRUCTURAL ..................................................................... 23
23. GROUTING FOR BASE PLATE / END PLATE ....................................................................... 25
24. ERECTION TOLERANCE........................................................................................................ 27
25. SUPPORTING DOCUMENTS ................................................................................................. 27

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1. PROJECT DESCRIPTION

PROJECT NAME : PROPOSED A & A TO EXISTING SINGAPORE AVIATION ACADEMY

LOCATION : NO 1 AVIATION DRIVE.
CLIENT : CIVIL AVIATION OF AUTHORITY OF SINGAPORE.
MAIN : SANCHOON BUILDERS PTE LTD.
CONTRACTOR
CONTRACTOR : ANDERCO PTE LTD.
CONTRACTOR : No.3 TUAS VIEW CIRCUIT.
ADDRESS
DESCRIPTION : STEEL STRUCTURE FABRICATION & ERECTION.
TITLE : PROJECT QUALITY PLAN.
DOCUMENT NO : APL-QAQC-PQP-001
REV :0

2. PROJECT QUALITY PLAN REVIEW AND APPROVAL

I have reviewed the information contained in this project Quality Plan and agree:

Name P.Gobu T.Govind

Sr. QA/QC
Position QA/QC Manager
Engineer

Sign / Date

29-JAN-2024 29-JAN-2024
Client – QAQC Consultant
Prepared Checked
Approved Approved

3. ORGANIZATION QUALITY POLICY

Anderco Pte. Ltd. is committed to be a quality conscious contractor through the effective implementation
of our QA/QC Plan. CAAS, NO 1 AVIATION DRIVE. PROJECT is based on the applicable requirements
and applicable codes and standards. All Anderco personnel assigned to this project shall be indoctrinate
on this QA/QC Plan by the Project Quality Assurance / Quality Control personnel. All shall strive for quality
performance in the project activities.

The QA/QC Personnel has the responsibility and authority to identify, initiate, recommend, control
verify activities affecting quality.

3.1. QUALITY

3.1.1 Prompt Response

3.1.2 On-time Delivery
3.1.3 Quality Products

3.2. ENVIRONMENTAL

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3.2.1 Prevention of Pollution
3.2.2 Reduction of Noise Disturbance
3.2.3 Resource Conservation
3.2.4 Waste Management

3.3. OCCUPATIONAL HEALTH & SAFETY

3.3.1 Prevention of Injury

3.3.2 Reduction of ill health

4. PROJECT QUALITY OBJECTIVES

4.1. The work shall be performed throughout the execution period in accordance with the applicable
Specifications listed in the Client’s Tender document, approved for construction drawings, subcontract
requirements, approved Company QC Procedures, Quality Control Plans and works Method Statements.

4.2. The QA/QC Personnel shall maintain at site at all relevant updated copies of applicable project
specification, codes & standards.

4.3. QA/QC Plan, QC Procedures, and Work Method of Statements shall be controlled in accordance with
the company Quality Control Procedures for QA/QC Document & Data Control.

4.4. In the event of conflict, the most stringent from the list shall apply.
a) Project Drawings
b) Project Specification
c) Singapore Codes and Standards
d) Scope of Works

5. PROJECT SCOPE

This Project Quality Plan identifies the quality assurance and quality control requirements for the project. It
also involves the techniques and activities intended to ensure that all necessary inspection and testing
activities shall comply with the procedures, specifications, standards and drawings. This is to ensure the
implementation of the quality assurance activities and monitor Good Document Practices (GDP)
compliance with project procedures, specifications, standards, drawings and regulatory requirements (if
any).

6. DEFINITIONS

CAAS Civil Aviation of Authority of Singapore.

SB Sanchoon Builders Pte Ltd.
APL Anderco Pte Ltd
QA Quality Assurance
QC Quality Control
GDP Good Document Practices
GEP Good Engineering Practices
FI Field Instructions
RFI Request for Inspection
QOR Quality Observation Report
NCR Non-Conformance Report
QA Quality Assurance
QC Quality Control
ITP Inspection and Test Plan
WPS Welding Procedure Specification
NDE Non-destructive Examination
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FIR Field Information Request
TPI Third Party Inspection

7. INSPECTION TEST PLAN (ITP)

1.QC is to prepare inspection test plan (ITP) with accordance with Main Contractor
requirement’s and shall be generated for main contractor / Consultant, review and approve. Reference No.
APL-CAAS-ITP-001 Steel Structure Works.

2. ITP shall be marked up with verification and inspection requirement and agreed with contractor before start of
the work. The “responsibilities” columns (s) of the ITP define the responsibilities of the involved party’s
responsible personnel.

3. Approved Inspection and test plan shall be implemented during each and every stage of fabrication, to ensure
the work is carried out with full compliance drawings and specification / Code. The Inspection and approving
parties as per ITP shall ensure the quality of work at every level.

8. SPECIFICATION AND STANDARDS

The following specifications and standards shall be used in practice for Fabrication.

1. BS 4-1 Structural steel sections. Specification for hot-rolled sections.

2. BS 3692 ISO metric precision hexagon bolts, screws and nuts specification
3. BS 4190 ISO metric black hexagon bolts, screws and nuts specification
4. BS 4872-1 Specification for approval testing of welders when welding procedure approval is not
required. Fusion welding of steel
5. BS 6072:1981 Method for magnetic particle flaw detection Painting of buildings. Code of practice
6. BS EN 1090-2 Execution of steel structures and aluminum structures -
Technical requirements for steel structures
7. BS EN 10024 Hot rolled taper flange I sections. Tolerances on shape and dimensions
8. BS EN 10025-2 Hot rolled products of structural steels - Technical delivery conditions for non-alloy
structural steels
9. BS EN 10029 Hot-rolled steel plates 3 mm thick or above. Tolerances on dimensions and shape
10. BS EN 1011-1 Welding. Recommendations for welding of metallic materials.
11. BS EN 10279:2000 Hot rolled steel channels tolerances on shape, dimension and mass.
12. BS EN ISO 898-1 Bolts, screws and studs with specified property classes. Coarse thread and fine pitch
thread
13. BS EN ISO 898-2 Nuts with specified property classes. Coarse thread and fine pitch thread
14. BS EN ISO 898-3 Fasteners mechanical properties of fasteners made of carbon steel and alloy steel - flat
washers with specified property classes
15. BS EN ISO 9606-1 Qualification testing of welders. fusion welding - steels
16. BS EN ISO 17637 Non-destructive examination of welds. Visual testing of fusion-welded joints.
17. BS EN ISO 17638 Non-destructive examination of welds. Magnetic particle examination of welds
18. BS EN ISO 17640 Non-destructive testing of welds - Ultrasonic testing - techniques, testing levels, and
assessment
19. EN 10034 Structural steel - I and H sections tolerances on shape and dimensions.
20. EN 1993 Design of steel structures - Eurocodes
21. ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test
methods.
22. ISO 3834 Quality requirements for fusion welding of metallic materials
23. ISO 11970 Specification and approval of welding procedures for production welding of steel
castings
24. ISO 12944-5 Paints and varnishes corrosion protection of steel structures by protective paint
systems.
25. ISO 14713-1 Protection against corrosion of iron and steel in structures zinc and aluminum coatings
guidelines.
26. ISO 15614-1 Specification and qualification of welding procedures for metallic materials welding
procedure test. arc and gas welding of steels and arc welding of nickel and nickel alloys.
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27. ISO 9001:2015 Quality Manual / Quality Procedure
28. NSSS – 1994 National Structural Steelwork Specification for Building Construction.

9. ROLE AND RESPONSIBILITIES

Project Manager

 Responsible for meeting the total requirement of completing the project within acceptable standard
quality, allocated time frame and financial budget.

 Establish and manage the project organization.

 Responsible for maintaining liaison and communication with the client and consultant.
 Responsible for an overall view of plans, methods, engineering system and budget to best execute and
control the project.
 Monitors total operation at site for control of engineering schedules, work schedules and project cost.
 Responsible for carrying out the cost evaluation, cost benefit analysis, and capability assessment of
vendor or sub-con to justify the ultimate cost effectiveness and efficiency.
 Communicates regularly with the client and/or his representatives for all works coordination at site.
 Responds to site requisition and ensure adequate quantity of tools, equipment’s, materials and
manpower are supplied.
 Assigns duties and defines areas of responsibility and authority to all site personnel.
 Liaise with Ministry of Manpower and NEA on occupational health and safety issues and other safety
statutory requirements for compliance at the project site.
 Monitor all works at the project site to ensure safe working environment is observed and always maintained.
 Prepare and implement the Project Safety Plan.

Construction Manager

 Manages the project site and organization.

 Communicates regularly with the client and/or his representatives for all works coordination at
project site.
 Responsible for maintaining liaison and communication with the client and consultant.
 Responsible for site planning and execution of engineering construction methods.
 To identify and disseminate the contractual obligation and area of responsibility.
 Assigns duties and defines areas of responsibility and authority to all project site personnel.
 Monitors overall operation at project site for control of engineering schedules, work schedules and
project cost.
 Monitors weekly and monthly work schedules for smooth interfacing of works.
 Responds to site requisition and ensure adequate quantity of tools, equipment’s, materials, and
manpower are supplied.
 Assis PM in preparing and implementation of the Project Safety Plan.
 Plan and implement Safety Promotion and Activities for approval by the PM.
 Assist PM to monitor all works at the project site to ensure safe working environment is observed
and always.

Site Engineer

 Clarifies with the client for any engineering discrepancies and technical problem encountered in the

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drawing as well as in practice.
 Monitors weekly and monthly work schedules to enable smooth interfacing works.
 Reviews work schedule for smooth supply of materials quantity required for different trades and
arranging the necessary machinery, tools, equipment for field application.
 Coordinates with the client for any site instruction and when problem arising on site.
 Coordinates with sub-contractors and vendors for smooth execution of works.
 Implements standard quality procedures and methodology of works on site.
 Ensures that the site works are carried out in accordance with approved drawings and specifications.
 Attends daily Toolbox meeting and encourages workers about safety rules and regulation practiced at site.
 Monitors daily progress and productivity and supervise the quality of works in accordance with
the work’s requirements.
 Implements safety rules, regulations, and instructions to ensure works and activities are performed safely.

QA/QC Manager

 To management of the Quality Assurance system.

 To development, implementation, up keeping and distribution of this project quality plan to QAQC Engineer.
 To ensures that Quality control Procedures (QCP), inspection Test form (ITP) are approved and revised in
accordance with the project document control procedures.
 Assist in co-ordination of inspections with Site QC Engineers / Supervisors notify inspections where required.
 Review and approve the final turnover package documents for completeness prior to turning over to the Client.
 To ensures that all non-conformance reports are logged, distributed, tracked and monitored in accordance with
the Quality Control Procedure, “Control of Non-Conformance”.
 Conduct and follow-up for Internal / External audit as per ISO requirements.

QA/QC Engineer

 Responsible for preparing Standard Quality procedures based on the project specification and requirements.
 Liaise with the client for all QA/QC matters.
 Prepares checklists for quality work and ensures that the site works are carried-out in conformance with
work quality plan.
 Responsible for documentation and compilation of QA/QC related documents.
 Ensures that the raw materials are inspected and tested in accordance with the material quality plan
before used on site.
 Witnessing of all site inspections.
 Coordinate all site inspections with the site subcontractor and RTO.
 Ensures that all non-conformances are reported, documented, and resolved in a timely manner.
 Ensure that all inspection reports are accurate and that all attached documents are status.
 Ensure all work is correctly prepared prior to any inspection being undertaken.

Planning Engineer
 Assists in the preparation of Project Execution Schedule including Resource allocation based on project
contractual requirement.
 Develops a well-defined and properly sequenced work activities in close coordination with the Project
Manager.
 Analyzes all contract data, establishes well defined work activities, and creates a comprehensive, properly
linked CPM schedule.
 Understands the flow and logistics needed for the execution of the project activities.
 Performs staff functions regarding Project Schedule, Physical Accomplishment based on Earned Value and

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activity sequence.
 Initiates and facilitates the development and maintenance of the project schedule.
 Inspects the project site and coordinate changes in project schedule.
 Prepares all related information needed to support the field operation requirement as far as construction
schedule is concerned.

Quantity Surveyor
 Responsible for Vendor/Sub-contractor assessment and to carry out price comparison before finalizing the
contract.
 Evaluate the claim/payments against the quantity and status of work done.
 Compares the contractual bill of quantities with the actual scope of work done and prepares additional claim if
applicable.

Site Supervisors

 Supervises workforce to ensure that the work is carried out in a safe manner.
 Supervises worker to ensure daily progress and productivity as required by the site is met.
 Supervises work to ensure that it is carried out as per drawing, specification, and instruction of Site Engineer.
 Ensures that the work carried out in sequence to minimize cost.
 Ensures all the required tools and equipment’s are in safe working condition and ready to use whenever
required.
 Checks the working area is safe from all kinds of hazards such as proper access, proper working
platform, and proper support to the formwork, adequate skilled manpower to execute the specific job.
 Attends Safety Tool Box Meeting every day prior to commence work for the day.

Lead Surveyor / Site Surveyor

 Controls Setting-out alignment and elevations for structural element on field.
 Liaise with Site Engineers for dispute and discrepancies in setting out works.
 Provides information and references to sub-contractor for survey related matters.

Safety Manager

 Responsible for meeting the total safety, health and environmental requirements as per company’s SHE
manual and that of the client.
 To assist the management to formulation of safety policy, rules standards, work practice and SM.
 To monitor the implementation of Safety Management at all work sites by conducting site inspection,
audits and taking follow-up action to ensure compliance.
 To review and recommend Safety provisions, equipment’s, system or plans for Safety improvement and
enhancement.
 To promote and enforce the use of personal protective equipment at work site.
 To maintain close liaison with relevant government authorities such as Ministry of Manpower (MOM) on matters.
 To investigate accident and serious safety incidents and make preventive recommendations.
 To monitor environmental problems and recommend control measures.
 To keep safety records and static’s, analyses and prepare monthly safely reports and other management reports.

Safety Coordinator

 Regulates safety procedures at site and enforce them.

 Prepares Job Safety Analysis and ensure overall safety of worker and safe use of tools and equipment’s.
 Monitors and checks to ensure safe working environment at all times.
 Instructs and briefs lifting and scaffolding supervisors with other field personnel to execute their respective works.
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 To maintain company’s safety statistics and records.
 To assist the Project Manager/HSE manager to identify any unsafe condition in the worksite or unsafe work
practice which is carried out in worksite
 To recommend to the Project Manager/HSE manager to implement reasonably practicable measures to remedy
any unsafe condition or unsafe work practice.

Steel Erector (Fitter)

 Fitter to determine if further modification required on site.
 Fitter to lead in modification works if required.
 To secure the steel members joint (eg : column to beam, beam to bracing) during the erection works.

10. QUALITY ASSURANCE MANAGEMENT

A. WORK QUALITY CONTROL

Inspection and Test Plans

 Inspection and Test Plans are to show how the works are monitored and recorded for assurance of quality and
relative to the approved design and specifications. The Inspection and Testing should include the ff:
 Method Statement demonstrating how the inspection and test plan facilities monitoring and recording of the
works quality assurance.
 Qualifications and experience and contact details of the persons who prepared the Inspection and Test Plan
 Qualifications and experience and contact details of the persons nominated as the Quality Assurance Officer
for carrying out the Inspection and Testing
 Details concerning the items to be inspected and/or tested
 Description of key quality criteria to be Inspected / Tested
 Activity being Inspected and Tested
 Methods of Inspection and Testing
 Frequency of Inspection and Testing
 Reference of standard required to be achieved
 Recording, reporting and notification requirements

Request for Inspection

 For inspection that requires witnessing of client consultant, Request for Inspection Form shall be used advise
the client / third party. Request 24 hours before inspection.
 Any client or third-party inspection activities shall be scheduled in the Master Inspection Log Submission as
detailed in the relevant Inspection and Test Plan. This gives clear notice of inspection to all concerned
parties in a timely manner.

B. PROJECT MONITORING AND CONTROL

Monitoring

Anderco will monitor the resource and time required to achieve acceptable criteria (the project quality
objectives) by review of its own sub-contractor performance.

Test checklists provide records of how a work task is performed.

In-process Inspection and Checking

Each stage of construction shall be inspected:

 By the supervisor performing random inspection.

 By the site supervisor inspecting the output daily.
 By the sub-contractor comparing his or her work against an acceptable standard sample.
 The person performing the inspection shall perform the checks as per the details in the appropriate section of
the ITP.
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Final Inspection and Checking
Final Inspection shall be performed by either the Contractor or a delegated person. The inspection shall ensure
that:
 All stages of construction have been completed.
 The finished works are clean, in good repair and tidily presented.
 The product conforms to the appropriate drawings and/or specifications.

C. MATERIAL QUALITY CONTROL

Material Fabrication Inspection
 The project QA/QC Engineer shall conduct an independent monitoring to verify the product’s quality being
maintained.
 The client shall be afforded the right to verify the purchased product at the vendor premises. Verification
activities by the client shall not preclude them from subsequent rejection of the products submitted to them.
 Record of inspection shall be recorded (signed and dated) by the QA/QC Engineer.

Material Delivery Inspection

 Material delivery shall be inspected by the QA/QC Engineer / Appointed Personnel to ensure that all materials
delivered are according to required specification and in good condition. All delivery orders shall be duly signed
and dated.
 Any non-conformity such as damages, inferior quality, lack of supporting documentation, etc. are to be
recorded in the delivery order and subsequently reported to the PM and/or Project Quality Surveyor who
administer the purchasing.
 Material Receiving Inspection form shall be filled up and signed off.

1. All Structural steel materials to be used for this project shall be in accordance to the following.
S.No. Description Standard / Tolerance Grade
1. Universal Beam / Column BS EN 10025 S275, S355, S460
BS EN 10210 – Hot Finish
2. Hollow Section S275, S355
BS EN 10219 – Cold Finish
3. Plate / Flat bar BS EN 10025 S275, S355
4. Angle bar / Channel BS EN 10025 S275, S355
5. Cast in Bolt / Anchor Bolt BS 4190 8.8
6. Fasteners (Bolt/Nut/Washer) BS 4190 8.8 / 8 / F436

Material Test Reports

As required in the Inspection Test Plan, all materials test reports shall be kept accordingly and monitored by the
QA/QC Engineer. A copy shall be submitted to client. A material Test Report Log shall be maintained and update
regularly by the QA/QC Engineer.

Midpoint / Audit

Quality Audits (on Lower-tier Subcontractors) shall be carried out as per the audit schedule.
Distribution on Quality Audit Reports shall be in accordance with the Company Quality System

Procedure for Quality Audits.

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Corrective & Preventive Action shall be verified, and audit non-conformances closed out as mentioned in
the Company Quality System Procedure for Quality Audits.
Anderco to do a Midpoint QA/QC review at 75% construction completion.

D. CONTROL OF DOCUMENTS

 A proper site document filling system shall be established and maintained for various incoming and
outgoing project documents and records in order to provide evidence of conformity to requirements
and of the effective operation of the quality management system.
 Welding Procedure Specification (WPS), Procedure Qualification Record (PQR), Welder
Qualification Record, Testing, Inspection and other fabrication procedures that will be used for the
performance of all work shall be reviewed and approved and shall be made available for review,
prior to the commencement of the associated activities.
 Anderco QC forms shall be used for all necessary inspection and testing activities leading to
completion and handover. The completed forms shall be complied with agree indexing in the
handover dossier.

E. CONTROL 0F NON-CONFORMITIES, CORRECTIVE /PREVENTIVE ACTIONS &

CONTINUAL IMPROVEMENT

Non-Conformance

 Non-Confirming work or product shall be segregated from the conforming materials. Re-occurrence of
problems leading to non-conformance should be eliminated or minimized by implementing appropriate
corrective and preventative actions. No repair on non-conforming works shall be undertaken prior to
the written agreement to do so by the appropriate level of management.

 Where simple re-work or adjustment is necessary to achieve required values, this is not considered as
nonconformity. Non-conformity is recorded if repeat testing establishes that replacement or repair is
necessary.

 The aim of the process control procedure is to ensure quality is achieved through initially correctly
action which will prevent non-conformance activities.

 Adherence to this plan will ensure that the quality problems are resolved in a controlled and
progressive manner and to avoid major re-work at final inspection stages.

 When the work carried out does not meet the agreed procure / when defects are noticed in the
material, non-conformance report shall be raised by the QC personnel. The report shall then be
reviewed and approved by the approving authority. The problem severity shall be identified in the NCR
report as minor / serious / critical. Upon the receipt of non-conformance report shall be reviewed and
necessary.
Corrective actions are to be implemented as listed below:
 To review the root cause of the problem / defect
 Increase the inspection surveillance
 Preventive action is continued until the work is performed within the quality requirement.
 Upon the rectification of the problem / defect, corrective action report is prepared, and preventive
measures are implemented to avoid the reoccurrence in the future.
 The work shall be re-inspected and upon getting the approval, the work can be continued further.

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Continuous Improvement Processes

When Project Quality Planning is being undertaken effectively in a project, there will usually be areas
identified for improvement. By reviewing and monitoring of output processes and project processes,
opportunities for quality improvement can identify and then improvement implemented throughout the life of
the project.

11. PREPARATION FOR FABRICATION

1. Plant Manager / Fabrication Manager to establish and maintain the overall layout of the fabrication yard
including areas which have been allocated to sub-contractors.
2. Plant Manager or Production Supervisor to identify the Team Leader for each fabrication work (either
by company or sub-contractor).
3. Team Leader to consult Plant Manager, Production Supervisor, or Project Manager on matters relating
to progress and any problems encountered during fabrication.
4. If available, Contract / Project Dept. to provide Team Leader with relevant engineering / shop drawings
for fabrication works through Production Dept.
5. Wherever possible, identities of the fabricated element parts to follow that shown in the engineering /
shop drawings.
11.1 CUTTING PLANS

The cutting plan shall be prepared before commencement of fabrication for all fabrication drawings.

11.2 STRAIGHTENING

All steel materials shall be straight and free from bends or twists. If the sections are distorted or twisted
during transit, storage etc. They shall be straightened and/or flattened by straightening machine at ambient
temperature, though minor bends may be corrected by limited heating under supervision.

11.3 BENDING

The bending of plates and sections to specially required shapes shall be done either on appropriate bending
machine or black smithy processes.

11.4 CUTTING

Cutting equipment following as per below table

S.No Description Cutting Equipment

1. Universal Beam / Column / Band Saw Machine, Automatic Gas Cutter & Semi-Automatic
Hollow Section Gas Cutter.
2. Plate / Flat bar CNC, Automatic Gas Cutter, Shearing Machine
3. Angle bar / Channel Band Saw Machine, Automatic Gas Cutter
4. Cast in Bolt / Anchor Bolt Band Saw Machine

Cutting edges of all plates shall be perfectly straight and uniform throughout. Cut edges shall be visually
examined for laminations and inductions.
Roughness and notches of cut surface shall be ground smooth.

11.5 HOLES

When holes are being drilled in one operation through two or more separable parts, which shall be separated
after drilling and burrs shall be removed. Finished holes shall not be more than 2.0 mm larger in diameter
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than the diameter based on size of the bolt passing through them. Holes for bolts shall not be formed by a
gas cutting process. Wherever a horizontal member is likely to collect water suitable holes for drainage shall
be provided. Slot holes should be used by drilling / gas cutting process. Refer SS EN 1090-2.

11.6 NOTCHES

The ends of all joints, beams and girders shall be cut truly square unless required otherwise and joist flanges
shall be neatly cut away or notched where necessary, the notches being kept as small as possible.

11.7 EDGE PREPARATION SURVEILLANCE INSPECTION

The edges or surfaces of parts to be joined by welding shall be uniform, smooth and cleaned from all foreign
materials such as moisture, slag, oil, grease, paint, scale or rust.

Welding groove dimensions shall be inspected as per shop drawings under tack-welded condition prior to
welding.

The allowable misalignment of adjoining plates to be butt-welded shall be in accordance with BS 5135.

Unless otherwise specified, the tolerance for welding groove dimensions shall be as follows:

a) Groove Angle : +/- 5 Deg.

b) Root Gap / Root Face : Subject to welding procedure specification.

11.8 BACK GOUGING INSPECTION - (If required)

Back gouging surfaces shall be visually checked, to be free from any surface defects / discontinuity.

11.9 Fit-up and ASSEMBLY

1. The fabricated components shall be assembled in such a manner that they are neither twisted nor
otherwise damaged and shall be so prepared that the specified chamber, if any is provided. In order to
minimize distortion in a member the components shall be positioned by using clamps, clips, jigs and other
suitable means and fasteners shall be placed in a balanced pattern.

2. If necessary, Items like roof trusses, galleries, plate girders etc. shall be trial assembled keeping in view
the actual site conditions prior to dispatch to site for erection so that they can be conveniently pre-
assembled during erection. Necessary match marks shall be made on these components before
disassembly in the shop and dispatching.

3. For columns that are fabricated in two or more parts pre-assembly shall be carried out in the fabrication
yard before dispatch to the erection site.

4. Ensure that qualified tack welders are performing that tack welds.

5. Preheat is not mandatory for single- pass tack welds which are re melted and incorporated into
continuous Flux cored arc welding.

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6. Remove tack welds that contain cracks thoroughly and replaced with new tack welds.

7. Tack welding shall neither as a rule not be made at the end and corner angle of a joint nor at the start
and end points of welding nor in such other position where tack weld may adversely affect the strength or
workmanship.

11.10 BOLTING

1. All bolt and nuts shall be used as per approved shop drawing and specification.

11.11 Treatment of the Friction Joint surface of High Strength Bolts

1. The contact surface of the members friction-joined with high strength bolts shall be free of paints or any
applied finish, oil, dirt, loose scale, burs and other defects which would prevent solid seating of the parts
or would interface with the development of friction between them.
2. Friction surface shall be visually inspected and grinding to
be adopted to remove any particle.

11.12 Marking and Identification

1. All structural steel shall be prominently marked for identification prior to assembly. The marking systems
shall be as follows:

 Direct stamping of member

 Paint marking

2. Items shall be carefully and accurately marked in accordance with approved shop drawings.

12. FABRICATION PROCESS

12.1 FITUP INSPECTION

1. Production Supervisor or Team Leader to supervise fabrication works to ensure that they are carried out
in accordance with appropriate engineering / shop drawings, specifications and Works Quality Plan –
Fabrication Process.
2. Prior to assembly work, the materials shall be checked against the approved shop drawings in terms of
quality as well as identification / markings.

3. Members to be welded shall be brought into correct alignment and held in position by suitable devices or
by tack welds unit welding is completed, to assure the most suitable welding position and accurate
assembly.

4. If required, cambering shall be provided in accordance with the consultant’s design and formed by
manual / mechanical means.

5. Production Supervisor shall raise the Request for Inspection (RFI) form QAQC-INS-10 to the QC Dept.
for fit-up Inspection.

6. The material specification and dimensions shall be verified based on applicable drawing.
7. Fit up alignment shall be verified using steel rules and spirit level. Edge preparation and weld fit up ·shall
be verified with respect to the applicable drawing & WPS. Welding joints constructed must follow
approved drawings.

8. Check the dimensions of the assembled structure like overall length, overall height, spacing between
members and angle.

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9. Full Penetration Butt Weld (FPBW), Groove angle and root gap shall be verified using templates / Root
gauge / Taper gauge.

10. QC to inspect all fabrication works carried out within the fabrication yard using the applicable inspection
report & Approved Drawing.

11. QC is to highlight any minor defects / non-conforming works to the Team Leader and ensure that they
are rectified before allowing the work to proceed to the next work processes.

12. QC will record those defects / non-conforming works that are extensive or has a major adverse effect on
quality and productivity in the Corrective / Preventive Action Request Form.

13. QC shall raise the inspection request to the main contractor / consultant for fit-up inspection. Reference
No: QAQC-INS-07 – Fit-up Inspection Report.

12.2 WELDING

Welding procedure qualification and welder’s operators’ performance qualification test shall be made in
accordance with BS EN 9606-1 2017 approved project specifications.

If existing WPS available, then that will be followed. New WPS need not be established.

12.3 WELDING ELECTRODES

1. Assistant Production Engineer / Fabrication Engineering foreman is responsible for control of welding
material to be used on the job as per weld Map and WPS.

2. Store Keeper has fundamental knowledge of welding material and is able to distinguish the type of
welding electrodes and rods to prevent misuse. Incoming goods Inspection report / Stores inspection
Report of the all-welding electrode, rods & fluxes shall be prepared and offered to QC Engineering for
inspection.

3. All batch certificates of welding electrodes, rods & fluxes are reviewed, accepted and maintained by QC
Engineer.

4. Welding electrodes and rods shall be stored in racks and shall not be stored directly on ground, and not
be opened until just before use.

5. Welder draws electrodes and rods from storekeeper using welder ID.

6. Different types of welding consumables shall not be mixed in baking ovens, holding ovens and
portable ovens.

7. In case of vacuum-packed electrodes / hermetically sealed containers, they can be used on the job
directly without baking as per the manufacturer’s instructions. If the package has been open for more
than 12 hours re bake at 350OC for 2 hours.

8. The moisture sensitive electrodes are baked in the Baking Oven as per the recommendations of
electrode manufacturer. After required baking is completed at the temperature recommended by
electrode manufacturer, the electrodes are transferred to the holding oven, which is kept at temperature
recommended by the manufacturer. The baking temperature recommended by the various
manufacturer’s brands of electrodes are given in the following table:1
Manufacture Kobelco
Drying Temperature & Time 300 -350 °C for 1 Hours
Holding Temperature
70°C - 120°C
Minimum

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NOTE: Drying is required only if the electrodes are kept outside for more than 8 hours.
In case manufacturer’s instructions are not available, electrodes are dried at temperatures provided in
the following table : 2.

Parameters Carbon & Low alloy steel

Drying Temperature 310° C ± 50° C
Drying Time 1 Hrs Minimum
Holding Temperature 70°C - 120° C

Manufacture Kobelco
S.NO E6013 (RB-26) E7016 (LB-52) E7018 (LB-52-18)
Classification AWS A5.1 AWS A5.1 AWS A5.1
Diameter 2.5 to 5mm 2.5 to 5mm 2.5 to 5mm

12.4 HANDLING OF WIRES:

1. All cored wires should avoid direct contact with water or moisture. Solid and flux cored wires shall be
removed from packing just before use.

2. At the end of each shift the wire suitable covers shall cover spools and it will avoid contamination of the
wires.

3. If the wires are not used in the consecutive two shifts, the spools shall be stored in the environment-
controlled room in covered condition.

S.NO E71T-1 E81T-1

Classification AWS A5.36 AWS A5.36
Shielding gas C0₂ C0₂
Diameter 1.2 to 2.0mm 1.2 to 2.0mm

12.5 SEQUENCE OF WELDING

1. The sequence of welding shall be selected to ensure that the components assembled by welding are
free from distortion and large residual stresses are not developed

2. Butt weld in flange plates and / or web plates shall be completed before the flanges and webs are
welded together.

3. The ends of butt welds shall have full throat thickness. This shall be obtained on all main butt welds by
the use of run off and run-on pieces adequately secured on either side of main plates. Additional metal
remaining after the removal of extension pieces shall be removed by grinding or by gas cutting.

12.6 Notes on Welding

1. Run-on and run-off plates shall be welded at the ends of welds lines of crucial butt welds. The length of
run-on (off) plates shall not be less than 30mm. When removing the run-on and run-off plates by flame
cutting, the cut shall not be nearer than 3mm to the side of the parent metal and the remaining metal
shall be removed by grinding. The grade of material is to be identical to that of the material being
welded.

2. Prior to welding, root opening, groove angle, and the crucial dimensions shall be checked and groove
face shall be free from oil, wasted water and dirt.

3. In case of complete penetration groove weld, the bottom of weld metal of first run shall be back chipped
by air gouging before the application of back run welding. The back chipping shall be applied to such
extent that the first bead of the front run is removed or sound metal of the first groove weld becomes
exposed The depth and width of back chipping shall be uniform along weld line. Gouged surface shall be

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dressed by grinding and wire brush. Prior to welding of back run, gouge surface area shall carry our Dye
Penetrant Test in order to determine the area is free of discontinuities.

4. All reinforcement shall be removed where weld form part of a contact surface. It shall bend smoothly into
the plate surfaces with transition areas free from edge weld undercuts.

5. Fillet welds terminating at the ends or sides or parts or members shall be returned around the corners for
a distance of not less twice the size of the weld.

6. All welding is to be carried out in an approved environment and if necessary additional protection may be
required. All joints are to be dried prior to welding

7. In case of multilayer’s weld, slag and spatter on each completed bead shall be removed prior to the start
of welding for the following, Arc strikes area of permanent welds is prohibited. Cracks or blemishes
resulting from arc strikes shall be ground to a smooth contour.
8. Where butt welds are to be ground flush there shall be no loss of parent metal.

12.7 Control of Distortion and Shrinkage

In order to minimize the distortion and shrinkage by welding, the following measure shall be
taken.

1. The size of welds and reinforcements should not be larger than 3mm.

2. The procedure and sequence of assembling shall be such as will minimize distortion and
shrinkage.

3. Jigs shall be used to control distortion and shrinkage.

4. Distortion of each part shall be corrected prior assembly.

12.8 PREHEATING

1. Preheat part to be welded by means of gas flames or induction heating to bring the specified preheat
temperature on the full thickness of the base metal for a distance equal to the thickness of the part being
Welded but not less than 75mm from the point of welding.

2. The preheating temperature is as per WPS follow.

3. The temperature shall be measured by means of thermal chalk or temperature indicating crayons
that will melt at the specified temperature at about 50mm away from the weld line.

4. Where local condensation is likely due to temperature changes, such as at early morning
recommencement of Work, localized gentle preheat of parts shall be applied before welding.

12.8 VISUAL INSPECTION OF WELDS

1. Production Supervisor shall inform to the QC Dept. for visual Inspection.

2. Production Dept. to maintain and update the Welder’s Qualification Test Records for all qualified welders
in the company including sub-contractors who have been appointed to carry out welding activities.

3. Welding inspection shall ensure all parameter and condition.

4. As per WPS/PQR welder has been full filled preheat temperature before, during and after Welding.

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5. All welding will be visually inspected to check if that there are defects such as undercut, crack, Porosity,
slag inclusion, Lack of penetration, under fill and spatter.

6. The size and thickness of welds will follow as per the specifications / shop drawings.

7. All welding surfaces to be cleaned thoroughly before welding and all slag to be removed after welding.
8. Weld surface(s) shall be verified for the finish and cleanliness.

9. The leg size of fillet weld should be in accordance with the Approved drawing. Fillet welds shall be
verified using fillet gauges.

10. Cleanliness of Inside bore shall be inspected using torch light / hand lamp.

11. All parts shall be thoroughly cleaned all dirt, welding electrode stubs and foreign matter shall be removed

12. 100% visual inspection shall be carried out for external defects.

13. QC shall raise the inspection request to the main contractor / consultant for visual inspection & NDT Test
Witness.

14. All inspection result shall be reported in visual inspection report. Reference No: QAQC-INS-08 – Visual
and NDT Inspection Report (TPI).

15. The surfaces of the finished welds shall be suitable to permit proper interpretation of MPI / UT and other
required nondestructive examination.

16. All non-destructive testing (NDT) shall be performed as per approved TPI agency as per the contract in
accordance with the requirements of the applicable standards and project specifications.

17. QC or Site Supervisors / Engineer shall conduct shear stud bend test and Bolt torque test (if required)
with witnesses of main contractor / consultant.

12.9 NON-DESTRUCTIVE EXAMINATION (NDE)

All non-destructive examinations shall be performed in- house in accordance with the requirements of the
applicable standards and customer’s specifications.

Personnel for NDE shall be qualified in accordance with PCN, ASNT recommended practice SNT-TC-1A.

 General requirement of Magnetic Particle Examination (MT)

Magnetic particle Examination procedures shall be in accordance with ISO 17638:2016, the evaluation
of indications and the acceptance criteria shall be in accordance with ISO 23278:2015. (The work done
by Independent Parties and work approved by Anderco QA/QC personal)

 General requirement of Ultrasonic Examination (UT)

The Ultrasonic Examinations of procedures shall be in accordance with ISO 17640:2017, the evaluation
of FPBW and the acceptance criteria shall be in accordance with ISO 11666:2018. (The work done by
Independent Parties and work approved by Anderco QA/QC personal)

 General requirement of liquid penetrant examination (PT)

Liquid Penetrant Examination procedures shall be in accordance with BS EN 571 –1.
The evaluation of indications and the acceptance criteria shall be in accordance with BS EN 571-1
(The work done by Independent Parties and work approved by Anderco QA/QC personal)

 General requirement of Radiographic Examination (RT)

If applicable. The work done by Independent Parties and work approved by Anderco QA/QC personal.

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13. DIMENSIONAL INSPECTION
1. The fabricated steel structure shall be inspected in accordance with respective approved
fabrication drawings and specification

2. QC / Production Supervisor will check overall length, orientation, diagonal measurement and all other
dimensions shall be verified and recorded

3. If dimension is not with required tolerance the member shall be corrected prior to further process.

4. All dimensions shall be recorded in Visual inspection report. Reference No: QAQC-INS-05. Visual
Inspection Report.

13.1 GENERAL TOLERANCES

The following standards / specifications shall be used:

 EN 10034: 1993 - Structural steel I and H sections – Tolerances on shape and dimensions.
 SSEN 1090-2 - Technical requirements for steel structures
 NSSS – 1994 - National Structural Steelwork Specification for Building Construction.

Description Acceptance standards

1. Main member / Partial
assembled component
1a. Physical Dimensions 1.Cross sectional tolerance should not be less than the structural
steel specifications or approved plan
2.Tolerance for length of structural steel member ±3mm
2 Welding 1.Weld size, length and profile shall meet the structural steel
specifications and drawing
2. Visual inspection shall meet the structural steel specifications
3. All Weld shall follow approved welding procedures
4. All welding must be done by qualified welders.

14. SURFACE FINISHING INSPECTION

14.1 CLEANING

All particles of grid filling or other foreign material that shall be removed from finished fabricated structural
steel. Sand blasting / Shot blasting shall be carried out if contractually agreed, to comply with BS 7079
Preparation grade Sa 2 ½ or approved specifications.

14.2 PAINTING INSPECTION

1. QC will be checking all surface prepared for painting are to be inspected and the Surface preparation
standard and paint used shall be reviewed and approved by Client/Customer prior to the start of the work.
(Refer to PJC)
2. QC / Production Supervisor, Before, During, After Painting process Check, Monitor & Record.

3. Ensure to check surface preparation to prior to primer Coat. E.g. (surface must be free from any rust,
scale, welding flux, spatter, oily film, dirt. Grease, salt etc...

4. Ensure to check each coating Dry Film Thickness (DFT) & Re-Coating Interval Time.

5. QC shall raise the inspection request to the Customer / consultant for painting inspection. (if required)

6. QC, all DFT (Dry Film Thickness) reading shall be recorded in painting inspection report.
Reference No: QAQC-INS-03 – Painting Inspection Report.

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14.3 GALVANIZING INSPECTION (Hot Dipped Galvanizing)

1. The inspection of finish and appearance is done with an unmagnified visual inspection, which is
performed by fully observing all parts and pieces of a hot-dip galvanized product to ensure all
specifications have been met.

2. Visual inspection is done in order to observe surface conditions (both inside and outside) and to check
all contact points, welds, junctions, and bend areas.

3. The visual inspection should be complete at the galvanizing yard before delivery.

4. Coating Thickness Gauge can be used for measuring galvanizing thickness on steel at the galvanizing
yard.

5. Steel members shall be hot-dipped galvanized to BS EN ISO 1461:2009 as per below table.

6. Areas that are uncoated / areas of galvanized damaged by welding, cutting or during transit shall be
reinstated by using Cold Galvanizing Zinc Coating. The surrounding galvanized area affected by the
heat of welding shall be reinstated similarly.

15. CONTROL OF NON-CONFORMANCE PRODUCT

15.1 IDENTIFICATION AND SEGREGATION

When a Non-conformance product (NCP) is detected, it shall be marked “on-hold” and segregated from the
other conforming items, where applicable. A NCP area shall be identified at the workshop to temporary store
these NCP till their disposition. If NCP is detected during in-process inspections, the work shall be on hold till
the root cause of the problem is eliminated. This shall be recorded on the Nonconforming Product Report.

15.2 NON-CONFORMING PRODUCT REPORT _ NCP

The QC Inspector shall prepare the NCP report. The report shall contain the following:

+ Description of nonconformance
+ Method of Disposition
+ Corrective Action
+ Verification

16. FINAL INSPECTION

This inspection shall be made to confirm whether the inspection or tests specified in the inspection
procedure have been carried out with satisfactory results.
Preparation for shipping /dispatch shall be in accordance with customers’ specification.

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17. DELIVERY TO SITE
Quality control department shall release the prefabricated materials via Inspection Release Note.
The material control department shall proceed with packing of fabricated material with suitable packing
material to avoid damages to paint.

Fabricated material shall be properly secured with packing strip.

The material control department shall prepare delivery order accordance with Inspection Release Note to
dispatch the material.

18. RECEIVING OF FABRICATION MATERIAL

1. The Site Engineer / Site Supervisor inspects the materials against the D.O and project specifications. On
acceptance he will arrange for material inspection with client / consultant.
2. Any material, which does not comply with specifications, codes, standards and client requirements shall
be issued a Non-Conformance Report (NCR) and the material shall be placed on “HOLD”. The non-
conforming materials shall be identified by “Red” color tag until the NCR has been closed, which will
dictate whether the material / equipment is processed further or to be returned to the supplier.
3. In case materials does not meet complete requirements as per D.O. Standards and specifications or,
the material shall be placed on “HOLD”.
4. For materials / products in loose bulk form or of large quantity where it is not possible to examine
completely upon delivery, appropriate random visual checking to be carried out.

5. The QA/QC Engineer shall co-ordinate such activities, and the Project Manager shall be kept informed
through Inter office Correspondence / Quality Observation Record.
6. Where delivered materials / products did not pass the necessary inspection and / or test, QC /
production Supervisor or Procurement / Site Supervisor to ensure that they are segregated and identified
by tags or labels or other appropriate means with the following information:
 Not for Issue
 Not for Use
 Not Inspected / Tested
 Rejected
 On Hold
7. All delivery orders to be duly signed by Site Engineer / Site Supervisor them before forwarding to the QC
Dept. for material inspection.
8. Materials are which comply with requirements shall be kept in stock and are identified by location /
project.

19. PREPARATION FOR ERECTION

19.1 ERECTION SCHEDULE

A master schedule shall be prepared for the whole package based on the contract original programmed.

19.2 ASSEMBLY

The fabricated components shall be assembled in such a manner that they are neither twisted nor otherwise
damaged and shall be so prepared that the specified chamber, if any is provided. In order to minimize

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distortion in a member the components shall be positioned by using clamps, clips, jigs and other suitable
means and fasteners shall be placed in a balanced pattern.

If necessary, Items like roof trusses, galleries, plate girders etc. shall be trial assembled keeping in view the
actual site conditions prior to dispatch to site for erection so that they can be conveniently pre-assembled
during erection. Necessary match marks shall be made on these components before erection.

For columns that are fabricated in two or more parts pre-assembly shall be carried out in the site yard before
erection. Erection sequence follow as per the Method statement and site condition.

20. ANCHOR BOLT INSTALLATION

20.1 BASE MATERIAL

1. Concrete foundation / Concrete wall

20.2 APPLICATIONS

1. As per drawing / Substitution of misplaced / Missing anchor rod.

2. Fastenings requiring seismic qualification
3. Structural coronations with post-Installed anchor (ag. extension/ connection to voila, slabs, stairs,
columns, foundations, etc.)
4. Anchoring structural steel connections (e.g. steel columns, beams, etc.)
5. Anchoring secondary steel structures (e.g. balustrades steel ledgers, etc.)
6. Anchoring crash banters, nets barriers, etc.

20.3 TECHNICAL DATA

1. Base material condition Dry, Submerged, Water-filled, Wet

2. Environmental conditions Indoor / Outdoor condition
3. Type of fastening Pre-fastening, Through-fastening
4. Cleaning procedures Manual air pump cleaning, Hand Compressed
5. Material composition Epoxy adhesive
6. Installation direction All

Refer photo for steps

anchor bolt planting

Substit

1
2 3 4

21. ALIGNMENT OF STEEL STRUCTURAL WORK

21.1 INSTRUMENTS

1. The following instrument shall be used to check the steel structure levels, verticality and distance
between the references.

 Auto level
 Total station

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2. Project datum line and level shall be provided by the customer / consultant. This will be act as a project
reference point.

3. Carryout the survey work and mark the X and Y co-ordinate as per drawing grid line.

4. Mark the centerline of a column structure as well as base plate.

5. Provide necessary packing plate prior to erection of column.

6. Ensure that the Survey Instrument valid calibration certificate shall be available at site.

7. Place the column over the packing plate as per drawing orientation and match the X and Y co-ordinates.

8. Check the levels by using Auto level, Dumpy level or total station and adjust the packing plate if
required.

9. Levels shall be adjusted by using the steel wedges below the column base plates.

10. Verticality to be checked by means of Theodolite or Total station with respect to centerline of base plate
and column structure.

11. Verticality shall be adjusted by the Guy Wire & Chain pulley blocks.

12. Ensure that the levels and verticality are within the tolerances specified and survey report shall be
maintained.

13. Obtain the Inspection clearances from the client / consultant if contractually required.

22. BOLT TIGHTENING ON STEEL STRUCTURAL

22.1 BOLT MATERIAL VERIFICATION

All fastener materials shall conform to the requirement of the applicable standards and approved drawings.
Mill test certificate of the chemical analysis and physical properties of the material shall be furnished as
required in the specification for materials.

Fasteners make and grade, manufacturer identification of the material shall be verified with Material test
certificate.

In case mill test certificate not available then chemicals and hardness check test shall be carried out as per
material specification.

NON-PRELOADED BOLTS

Types of bolts Nuts Washers

Grade Standard Grade Standard Grade / Hardness Standard
BS EN ISO 4014
BS EN ISO 4032 F436, 100HV BS EN ISO 7091
8.8 BS EN ISO 4017 8
BS 4190 BS 4190 - BS 4320
BS EN ISO 4014
BS EN ISO 4032 F436, 100HV BS EN ISO 7091
10.9 BS EN ISO 4017 10
BS 4190 BS 4190 - BS 4320

22.2 HANDLING AND STORAGE

Bolts shall be stored in a covered shed. It shall be handled with care not to damage the threads.

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Any abuse of the bolts during handling or installation shall be prevented. Bolts having rust, dirt and damaged
thread should not be used.

22.3 BOLT HOLE

When holes are being drilled on structural member, drilling burrs shall be removed by using grinding.

Finished holes shall not be more than 2.0 mm larger in diameter than the diameter of the bolt passing
through them. Holes for bolts shall not be formed by a gas cutting process except in special case with
specific permission of the customer.

22.4 NON-PRELOADED BOLT TIGHTENING METHOD BY USING TORQUE MACHINE

1. All bolts shall be used as indicated on the shop drawings and the erection drawings.

2. At the time of assembly, the surfaces of the structural steel shall be thoroughly cleaned, free of oil, dirt or
other foreign matter immediately prior to assembly.

3. All bolts required for erection shall be included with the delivery of fabricated members for each unit or
structure in clearly identified containers.

4. After assembly of the structures, all bolts shall be installed by hand or using appropriate spanners (ring
type and open-ended spanner) in a sequential manner (diametrically opposite) for ordinary
bolting assemblies.

Complete the leveling, plumbing and alignment of the structures prior to bolt tightening.

After completion of the alignment, all the bolts of non-preloaded bolting assemblies shall be tightened by
using power tools (bolt runner) value 350Nm or appropriate spanner (ring type and open-ended
spanner) in a sequential manner (diametrically opposite).
5. Upon completion of the above bolt tightening.

22.5 MARKING RULE

1. As all the bolting assemblies are non-preloaded assemblies, the sung tight would be sufficient to tighten
the bolts, refer to the attached standard for reference.

2. To ensure the bolt tightness refer to the table in next page.

3. The contractor’s erection team shall tighten all the bolts by power tools (impact wrench or bolt runner) or
hand (snug tight) using appropriate spanners (ring type and open-ended spanner).

4. After tightening, the bolt (Head / Tail side) shall be marked a slanted line by suitable marker to ensure all
the bolts are tightened sequential manner.

5. Bolt tightening inspection has to be carried out to ensure all the bolts are fully tightened by using
appropriate spanner.

6. Upon completion of inspection, the bolts (Head / Tail side) shall be marked slanted opposite line (cross
mark) by suitable marker to ensure all the blots are tightened sequential manner.

7. The nut shall be a good fit on the bolts and one clear thread shall show through the nut when it has been
finally tightened-up, and at least one thread plus thread run-out is clear between the nut and unthreaded
shank of the bolt.

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22.6 SAMPLE MARKING SKETCH

AFTER TIGHTENING AFTER INSPECTION

22.7 INSPECTION

Inspection requirements are consisting the following:

1. Verify the proper fasteners were used for the assembly and connected members are fabricated properly

2. Bolted joints are drawn into firm contact.

3. During inspection by using open ended spanner hold it and hammering the spanner by hammer.

4. Inspection shall be carried out at random selection as per the batch.

5. The minimum torque requirements for tightness obtained by the full effort of a man using a standard
spanner. Approximate Torque value for Torque inspection refer to the table below.

6. The Client Sup / Engineer / QC and Client rep (RE/RTO) shall check 5% of each structures bolt
tightening.

Refer to the below table for torque value.

23. GROUTING FOR BASE PLATE / END PLATE

23.1 GENERAL-METHOD STATEMENT FOR NON-SHRINK GROUTING

1. Prior to use for the actual grouting application, Non-Shrink Grout (PRO GROUT S40F ECO) materials
must have available records of materials receiving inspection and acceptance as per specifications.

2. Prior to the final grouting application, all installed structural steel plates and supports must have records
of inspection as per the Inspection and Test Plan.

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3. Preparation of cement-based non-shrink grout materials and formwork inspection shall be in accordance
with specifications – mixing, placement, sampling, testing, curing, and final inspection.

4. The following step-by-step processes are based on the manufacturer’s recommendations and best
practices for grouting application:

23.2 PREPARATION OF THE FOUNDATION

1. Before installing the base plate, the concrete surface to be grouted must be prepared for chipping with a
chipping hammer, as appropriate. damage the surface and foundation is not permitted.

2. Chipping should cover the entire area that will come in touch with the grout. This will allow the grout to
adhere to the chipped surface of the concrete with a firm bond.

3. If a bolt anchoring system to the grout is used, the bolt pocket formers should be formed into a cone to
help prevent stresses from building up when the bolts are tightened and are transmitted directly to the
foundation.

4. Bolt pocket formers should be manufactured of materials that are simple to remove but leave a rough
concrete texture when stripped.

5. The chipped concrete surface, base plates, and holding down bolts, among other things, must be
cleaned and free of any oil, dust, debris, paint etc...

23.3 FORMWORKS

1. The surface foundation for formwork installation must be carefully cleaned, including bolt holes.

2. To prevent grout loss, fitted formworks around the base plates where grout is to be retained must be as
watertight as necessary.

3. The top of the formwork must be at least 25mm higher than the bottom of the base plate. When large
base plate pours are required, the formwork must be raised to allow a pressure head to form.

23.4 PREPARATION FOR GROUTING

1. Before beginning the grouting pouring application, make sure the formwork and concrete surface are
free of any dirt, dust, and debris.

2. Within 24 hours of grouting, the concrete surface within the formwork must be wet with water. Before
grouting, make sure the surface is moist

3. and in a suitable, acceptable temperature condition.

4. To enable a continuous grouting operation, mixing equipment must be suitable and in good operating
order, with backup mixing equipment accessible in the event of equipment failure.

5. Ensure that enough potable water is available for mixing and that the temperature is within the permitted
range specified in the material specification.

23.5 GROUT MIXING

1. After 24 hours of saturation compliance, fitted formworks must be assessed for probable leakage.
Ensure that all standing water, including water from the bolt pockets and surrounding area, is removed
prior to grout mixing. The concrete that will be poured with grout must be moist.

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2. Ensure that the materials and water mixture is in compliance with the materials specifications specified in
the material technical datasheets.

3. A heavy-duty drill fitted with a suitable paddle should be used to mix the grout in each bag at a slow
speed of 300-500 rpm (revolution per minute) for a minimum of 3 minutes. A dedicated grout mixer must
be used for multiple bags mixes to ensure consistency and a minimum permissible mixing time of 4-5
minutes to meet the acceptable and desired mixes prior to grout pouring.

4. When the grout mixture is lump-free, add enough water to achieve the desired consistency.

5. Take compressive test cube samples of non-shrink grouting materials, 50 x 50 mm cubes for each
grouting location / Building (compressive test cube samples 3 for 7th day and 3 for 28th day).

6. Ensure that a copy of the grout cube compressive test results is submitted to the project consultant for
their records.

23.6 CURING

1. After the grout is applied, wet rags should be used to cover the exposed edges to keep the grout moist
for 24 hours (If required).

23.7 MATERIALS

PRO GROUT S40F ECO

24. ERECTION TOLERANCE

Description Acceptance standards

1. Column verticality Tolerance for verticality: ±H/600 or 5mm, maximum ±25mm;
where H is the floor to floor height in mm.
2. Column position The position in plan of a steel column at the base shall not deviate
from the specified position by more than 10mm along either of the
principal setting out axes
3. Beam level 1. Maximum deviation of level at each end of the same beam: ±5mm
2. The level of the top of the steelwork at any storey shall be within
±10mm of the specified level
4. Beam position Beams shall not deviate from their specified positions relative to the
column to which they are connected by more than 5mm
5. Corrosion and fire protection
5a. Thickness of coating Average thickness of the coating or the protective layer must not be
less than specified
5b. Condition 1. No visible damages
2. No spalling of coating or protective layer from structural steel
members

25. SUPPORTING DOCUMENTS

25.1 FLOW CHART FOR QAQC STEEL STRUCTURAL FABRICATION & ERECTION

25.2 ORGANIZATION CHART

25.3 REPORTS / RECORDS

Following reports shall be submitted to customer / client / Consultant in accordance with requirements of
customers’ specification.
Inspection report shall be maintained by QAQC department and approved by the involved parties.
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25.3.1 QAQC-INS-03 Painting Inspection Report / Sub-con Report
25.3.2 QAQC-INS-05 Material Testing Report (Lab Report)
25.3.3 QAQC-INS-06 Material Inspection Report (In-Coming Material Checklist)
25.3.4 QAQC-INS-07 Fit-up Inspection Report
25.3.5 QAQC-INS-08 Visual inspection Report
25.3.6 QAQC-INS-10 Bolt Tightening inspection Report (At Site)
25.3.7 Steel Installation Checklist (At Site)
25.3.8 Delivery Order / Delivery Memo (If required)
25.3.9 NDT (MT / UT) Test Report (TPI Report)
25.3.10 Galvanizing Certificate (Sub-con Report)

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25.1

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