Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

Document No. : G3IR-1000-15-SP-9006_R1 Date 09 July 2012 Page 1 of 13

ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

Project Document No:

G3IR-1000-15-SP-9006

Unit: Discipline: Document Type:

General Civil Structural Architectural Specification

Document Title:

ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

ISSUED FOR CONSTRUCTION

05 Nov 2012

1 0 Revision

09 July 2012 25 May 2012 Date

Issued for Construction Issued for Approval Purpose

NB NB Prepared By

SM SM Checked By

VP VP
FLUOR BASF

Approved By

G3IR-1000-15-SP-9006_R1.doc

Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

Document No. : G3IR-1000-15-SP-9006_R1 Date 09 July 2012 Page 2 of 13

ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date Description

1 0

09 July 2012 25 May 2012

Issued for Construction Issued for Approval

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

Table of Contents
1.0 INTRODUCTION.........................................................................................................................................4 1.1 Purpose ................................................................................................................................................4 1.2 Scope ....................................................................................................................................................4 REFERENCES ..............................................................................................................................................4 2.1 Project Specifications .........................................................................................................................4 2.2 Industry Codes and Standards ..........................................................................................................4 2.3 Government Regulations ...................................................................................................................5 DEFINITIONS ..............................................................................................................................................5 GENERAL .....................................................................................................................................................6 4.1 Quality Control...................................................................................................................................6 4.2 Submittals............................................................................................................................................6 4.3 Performance Requirements ...............................................................................................................7 PRODUCTS AND MATERIALS ................................................................................................................8 EXECUTION.................................................................................................................................................9 6.1 Receiving, Inspection and Storage ....................................................................................................9 6.2 Erection ...............................................................................................................................................9 6.3 Structural Stability ...........................................................................................................................10 6.4 Setting Base Plates ............................................................................................................................10 6.5 Bolted Connections ...........................................................................................................................11 6.6 Welded Connections .........................................................................................................................11 6.7 Correction of Errors.........................................................................................................................11 6.8 Floor Plate and Grating ...................................................................................................................12 6.9 Metal Decking for Floors and Roofs ...............................................................................................12 6.10 Shear Connectors..............................................................................................................................12 6.11 Coating Repairs ..............................................................................................................................132

2.0

3.0 4.0

5.0 6.0

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

1.0 INTRODUCTION 1.1 Purpose This specification provides the structural steel erector with the requirements of steel erection for process industry. 1.2 Scope This specification describes the requirements for the receipt, handling, erection, assembly, and field inspection of structural and miscellaneous steel. In case of any conflicts or inconsistencies between this Practice, shop drawings, erection drawings or other contract documents, most onerous shall apply and it shall be brought to the attention of the buyer for resolution. 2.0 REFERENCES When adopted in this specification or in the contract documents, the latest edition of the following codes (along with amendments), standards, specifications, and references in effect on the date of contract award shall be used, except as otherwise noted. Short titles will be used herein where appropriate. 2.1 Project Specifications G3IR-1000-15-SP-0005 Specification for Fabrication of Structural and Miscellaneous Steel G3IR -1000-15-SP-0004 Specification for Non Shrink Cementitious and Epoxy Grout G3IR-1000-55-SP-9001 Painting Specification 2.2 Industry Codes and Standards IS 800 IS 816 Code of Practice for General Construction in Steel

Code of practice for use of metal arc welding for general construction in mild steel Code of procedure for inspection of welds
Steel for General Structural Purposes Specification High strength bolts in steel structures- Code of practice Safety code for Erection of Structural Steel Approval Tests for Welding Procedures Approval Tests for welders working to approved

IS 822 IS 2062 IS 4000 IS 7205 IS 7307 (Part 1) IS 7310 (Part 1)

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

Document No. : G3IR-1000-15-SP-9006_R1 Date 09 July 2012 Page 5 of 13

ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

IS 9595 IS 12843 IS 3696 (Part 1 to 2) IS 13416 (Part 1 to 5)

Recommendations for Metal Welding of Carbon and Carbon Manganese Steels Tolerances for erection of steel structures Safety code of scaffolds and ladders Recommendations for preventive measures against hazards at workplaces

2.3 Government Regulations Codes and Regulation by Centre, state or local agencies that have jurisdiction, where the structural steel is to be erected, shall apply. 3.0 DEFINITIONS buyer: The party that awards the contract to the erector. The buyer may be the owner or the owners authorized agent. buyers inspector: The authorized representative of the buyer with authority to act in the interest of, and on behalf of, the buyer in all quality assurance matters contract documents: Any and all documents that the buyer has transmitted or otherwise communicated, either by incorporation or reference, and made part of the legal contract agreement or purchase order between the buyer and the erector engineer of record: The buyers authorized representative with overall authority and responsibility for the structural design erector: The party that is responsible for the erection of the structural and miscellaneous steel. Unless otherwise noted, the term erector shall apply also to the erectors subcontractor(s) and/or vendor(s). erectors inspector: The authorized representative of the erector with responsibility for the quality control of all materials, installations, and workmanship furnished by the erector and any of the erectors subcontractors or vendors owner: The party who has authority through ownership, lease, or other legal agreement over the (site, facility, structure or project) wherein (what is to be provided or installed) will be used.

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

4.0 GENERAL 4.1 Quality Control A. The erector shall be solely responsible for the quality control of all the erector-supplied materials, installations, and workmanship. B. The erector shall have a written Quality Control Program and Inspection Procedures document that shall provide details of how compliance with the requirements of this Practice and the shop and erection drawings shall be achieved. The erector shall maintain a complete up-todate set of erection drawings at the jobsite. C. All welding procedures and individual welders shall be qualified in accordance with the requirements of IS 7307 (Part1) and IS 7310 (Part 1) respectively. D. All welding inspectors shall be qualified and experienced person. They shall be certified by an independent institution. E. The erectors inspector shall inspect all materials, installations, and workmanship of the erector to ensure conformance with the requirements of this Specification and the contract documents. F. The buyers inspector shall have the right to inspect all materials, installations, and workmanship supplied by the erector and shall have an unrestricted right of access to the erectors work areas. G. The buyers inspector may reject any improper, inferior, defective, or unsuitable materials, installation, and workmanship of the erector. Any rejected material, installations, and workmanship shall be repaired or replaced by the erector in accordance with the buyers instructions at no additional cost to the buyer. H. The erector shall provide all inspection tools and shall provide inspection access facilities such as platforms, ladders, and scaffolds as requested by the buyers inspector. I. Inspection tools and tool calibration records for tools used by the erector shall be maintained and available for examination by the buyers inspector.

4.2 Submittals A. The erector shall submit the following documents to the buyer for review before the start of erection: 1. 2. 3. 4. 5. 6. Safety program Quality control program and inspection procedures Welding Procedure Data Sheet Procedure Qualification Records (PQR) Welder(s) / Operators qualification records Assembly lift plan(s) as required by buyer

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Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

B.

If requested by the buyer, the erector shall submit the following documents to the buyer for recording purposes: 1. 2. Quality control inspections and test results Calibration or recalibration performed on the tools or equipment used by the erector during the work

4.3 Performance Requirements A. Safety 1. The safety program shall address the safety measures that the erector shall use during steel erection work. The safety program shall comply with the requirements of the contract documents; IS 7205, IS 800 and any other applicable state, or local requirements. The erectors safety program shall provide a detailed description of how the erector will prevent injury to all personnel involved in the erectors operations. The safety program shall include an effective system for initial orientation and education in safety and accident prevention, as well as appropriate records to document compliance. At a minimum, the safety program shall place particular emphasis on the following aspects: a. b. c. d. e. f. g. 3. Fall prevention and safety of men Ground-level preassembly to minimize elevated erection Hole covers and opening barriers Access control to incomplete areas of erection Lifting plans and hoisting procedures Safety against Fire Safety of Structure

2.

All preventive measures against workplace hazards shall be in strict accordance with IS 13416 (Parts 1 to 5), Contract documents and any other special requirements dictated by supplier.

B. Assembly Lift Plan 1. The erector is responsible for assuring that all preassemblies that are not specifically shown or noted on the design drawings to be preassembled before lifting will maintain structural integrity during lifting. Contractor shall prepare appropriate assembly lift plan. The assembly lift plan shall demonstrate that the proposed lift shall be performed safely and that the assemblies being lifted will remain free from distortion or undue bending, and will maintain structural integrity during the lift. The assembly lift plan shall contain detailed data on the extent of the lifted assembly, its weights, the structural calculations that prove structural stability of the assembled components during lifting operations, verification of the capacity capabilities for any cranes utilized in the lift, location and positioning of the cranes, and a description of the rigging to be utilized. Structural Engineering

2.

3.

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

4.

Review of the assembly lift plan by the buyer does not relieve the erector of responsibility of safe erection and/or lifting of any component, structural assembly, or any other item under the control of the erector.

5.0 PRODUCTS AND MATERIALS All materials supplied by the erector shall conform to G3IR-1000-15-SP-0005 (Fabrication of Structural and Miscellaneous Steel Specification), unless otherwise specified by the contract documents.

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

6.0 EXECUTION 6.1 Receiving, Inspection and Storage A. All materials designated for the care, custody, and control of the erector shall be received, unloaded, stored and otherwise handled in a manner that prevents distortion, deterioration, damage or staining. Materials shall be kept free of dirt, grease and other foreign matter. B. Unless otherwise required by the buyer, all materials shall be inspected by the erector immediately after receipt to ensure that the materials are not damaged, that all items on the packing list have been supplied and that all documentation has been received. C. If any damage is discovered or any parts, components or documentation are missing or otherwise defective, the occurrence shall be reported to the buyer in writing within 24 hours of material receipt. 6.2 Erection A. Erection shall be in accordance with the drawings and other contract documents, IS 7205, IS 800, and any applicable centre, state, municipal, or local regulations or codes. Erection tolerance shall be in accordance with IS 12843 unless otherwise specified in Design Drawings. B. Any circumstances discovered by the erector that affect progression, performance or completion of the erectors work activities such as discrepancies between the erection/shop drawings and the delivered steel members, incorrectly fabricated steel members or incomplete or unacceptable work of other contractors affecting the erectors work shall be immediately reported to the buyer in writing. C. Any damage caused during erection shall be reported to the buyer. Corrective measures shall be completed as directed by the buyer at no additional cost to the buyer. D. Temporary erection loads or permanent loads shall not be placed on any incomplete portions of the structure being erected unless the erector can demonstrate by analysis that the contemplated action is safe. E. Loose timbers, metal sheeting, bolt buckles, tools, debris, and temporary scaffolding shall be kept restrained or removed from work areas. The erector shall be responsible for securing all equipment and materials within the erectors care, custody and control during the erection operation. F. The erector shall maintain the job site in a clean and safe condition at all times and shall properly dispose of, off the premises, all crating, waste materials, and other refuse that has accumulated as a result of the erectors activities under this Specification. G. Lifting of painted structural members shall be done with a nonabrasive choker. H. The erector shall keep a daily record, by piece number, of all material erected. I. Before commencing work, the erector shall check foundations and other connection points to confirm their location, orientation, elevation, and condition.

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

J.

All scaffolds and ladders for construction shall meet the safety requirements mentioned in IS 3696 (Part 1 & 2).

6.3 Structural Stability A. The erector shall, at all times, be responsible for the adequacy and installation of any temporary bracing or guy cables required to counteract loadings imposed during erection. This responsibility shall also extend to temporary bracing required to ensure safe and stable conditions of partially completed structural assemblies. B. The structure shall be plumbed, leveled and braced before any final bolted or welded connections are made. 6.4 Setting Base Plates A. The erector shall clean the top of bearing surfaces and the bottom of base plates. The erector shall set and shim column base plates to correct positions, elevations and locations as shown on the erection drawings. Shims or wedges may be used and shall be provided by the erector. If setting nuts are used, they shall be loosened before grouting. B. Grouting of base plates shall be in accordance with Spec-G3IR-1000-15-SP-9004 (Specification for Non Shrink Cementitious and Epoxy Grout) and other contract documents. C. When required on the drawings, anchor bolts shall be tightened to the specified tension. Anchor bolts shall be fully tightened to the specified tension only after the base plates have been grouted. D. The erection of structural steel shall not commence until grouting and anchors have obtained sufficient strength to adequately support all the loads imposed upon them including any due to the erection operation.

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Structural Engineering

Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

6.5 Bolted Connections A. Where structural joints are made using high-strength bolt assemblies, the materials, methods of installation, tension control, types of wrenches to be used and inspection methods shall conform to the IS 800, IS 4000 and the contract documents. B. All bolts shall be as noted on the shop drawings, erection drawings, or other contract documents. C. Mechanically galvanized bolts and nuts shall not be intermixed with hot-dip galvanized nuts and bolts. D. Where Ordinary strength bolt Grade 4.6 assemblies are used for connecting appurtenances (i.e., handrail assemblies, pipe supports, gates etc.) to structural steel members, the bolts shall be tightened to a snug-tight condition. E. Galvanized High Tensile bolts of strength Grade 8.8 shall not be reused. F. The erector shall color code, die punch, or otherwise mark the ends of torqued bolts indicating that the bolts have been properly tensioned and are ready for inspection. 6.6 Welded Connections A. Welding shall be in accordance with IS 9595. B. All welds shall be continuous unless the buyer approves alternate procedures. C. Field welding shall not be used except as shown on the shop drawings or erection drawings. D. Minimum fillet weld size shall be 6 mm for structural welds. Seal welds shall be minimum 3mm fillet weld. E. Welds to connection plates embedded in concrete shall be deposited in a sequence that minimizes distortion of the embedment to +1/8 inch (3 mm) of flat or true. F. When the contract documents require welding to existing facilities that were constructed using steel other than Grade E 250B to IS 2062, the engineer of record shall provide a welding procedure. G. The Cost of corrective measures of all defective welds shall be in contractors account. 6.7 Correction of Errors A. Fit-up bolts and drift pins shall not be used to bring improperly fabricated members and parts into place (springing). Drift pins shall not be driven with such a force as to injure adjacent metal areas. B. When approved by the engineer of record, the erector may enlarge standard holes by 1 mm (1/16 inch) when necessary to make connections resulting from minor misfit. Holes in connections that misfit by more than 1 mm (1/16 inch) shall be corrected as directed by the engineer of record.

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Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

C. Enlargement of holes shall be made by reaming or drilling only. Flame cutting, burning, gouging, chipping, or drift punching shall not be permitted. D. No packing, shimming, filling, or wedging shall be permitted to correct faulty work unless approved by the engineer of record. E. One filler plate up to 3 mm (1/8-inch) thickness may be used as required in spaces between members to be bolted. The engineer of records approval shall be required for filler plate requirements greater than 3 mm (1/8 inch). F. All mismatch / errors as a result of improper erection or missing / erroneous information on drawing shall be brought to the Engineer of Record notice for resolution. 6.8 Floor Plate and Grating A. All field-cut floor plate or grating openings requiring toe plate protection or banding shall be installed as required on the design drawings or other contract documents. B. The erector shall fasten the grating and floor plate as specified on the design drawings. A minimum of four fasteners per panel shall be used. C. The method for fastening grating shall be specified on the design drawings. Non-removable grating shall be welded with 40mm long x 3mm fillet welds at 1/4th bearing bar maximum spacing and at each side of each panel. 6.9 Metal Decking for Floors and Roofs A. Floor and roof deck sheets shall be installed in accordance with the manufacturers installation instructions and the contract documents. B. The erector shall repair all sags, deformations, holes, and other irregularities. C. Where damage has occurred to shop-applied coatings on metal decking, field touch-up shall be in accordance with the manufacturers recommendations. 6.10 Shear Connectors A. All shear stud attachments shall be welded in strict accordance with the manufacturers recommendations for welding procedure and welding equipment. B. When two or more stud welding guns are operated from the same power source, the erector shall interlock the guns so that only one gun can be operated at a time to ensure that the power source has fully recovered from making one weld before another weld is started. C. All ceramic insulators shall be removed from the base of the studs after welding.

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Client Name: BASF India Limited Project Name: Project GIR Project Number : G3IR

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ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL

6.11 Coating Repairs A. The erector, in accordance with Spec-G3IR-1000-15-SP-0005 (Fabrication of Structural and Miscellaneous Steel Specification), shall repair all erection damage to hot-dip galvanized coatings. B. All erection damage to shop-applied paint coatings shall be repaired in accordance with the buyers coating specification. All galvanized bolt assemblies tightened against shop-applied paint shall be painted.

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Structural Engineering