Doc. No. Rev.

ENGINEERING & CONSTRUCTION

ENG-JOB-TBC-PRC-XXX A
PT KRAKATAU ENGINEERING
PT. KRAKATAU
ENGINEERING Date: 1-Sept-2016 Sheet 1 / 14
Job. No

Fabrication Method

Rev Date Page Description Pre'd Chk'd App'd

3
2
1
0 1/09/16 All Draft Issue MRW MRW FAN
 Sheet 2 / 14

PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

Table of Contents
1. SCOPE............................................................................................................................ 3
2. DEFINITION OF TERM...................................................................................................... 3
3. CODES, STANDARD, SPECIFICATION AND PROCEDURE..................................................3
4. GENERAL REQUIREMENTS.............................................................................................. 4
4.1 General........................................................................................................................................ 5
4.2 Reference to Design Drawing..................................................................................................5
4.3 Shop Drawing............................................................................................................................. 6
4.4 Erection Plan............................................................................................................................... 7
4.5 Review......................................................................................................................................... 7
5. PRODUCT HAANDLING................................................................................................................. 5
5.1 Delivery and Storage................................................................................................................ 5
5.2 Fastener....................................................................................................................................... 5
5.3 Placement................................................................................................................................... 6
6. MATERIAL....................................................................................................................................... 9
6.1 Delivery and Storage................................................................................................................ 5
6.2 Fastener....................................................................................................................................... 5
6.3 Replacement............................................................................................................................... 6
7. EXECUTION.................................................................................................................................. 10
7.1 Fabrication.................................................................................................................................. 5
7.2 Assembling................................................................................................................................. 5
7.3 Welding........................................................................................................................................ 6
7.4 Painting........................................................................................................................................ 7
8. TESTING AND INSPECTION........................................................................................................10
8.1 Material Inspection.................................................................................................................... 5
8.2 Dimensional Inspection............................................................................................................ 5
8.3 Welding Inspection.................................................................................................................... 6
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

1. SCOPE
This work method shall be applied for fabrication of structural steel work, Steel Structure and
Architectural Work HSM 2 Project in PT. Krakatau Steel, Cilegon-Indonesia.
Take delivery of raw steel, prepare shop drawings, fabricate, complete surface treatment, mark of
identification, pack, and crate or otherwise properly prepare for shipment, ship to the site all structural
steel indicated, or otherwise required for proper completion of the work.

2. DEFINITION OF TERMS
Within the contents of this work method:
Client means PT. Krakatau Engineering for whom Contractor is performing work or assignees who
are the end user of the facilities.
CONTRACTOR is PT. Wijaya Karya (Persero), tbk., the party specifying or purchasing the
material or equipment for and on behalf of the Client.
The SUBCONTRACTOR / VENDOR is the party, which manufactures or supplies the material
equipment and services to perform the duties specified by the Contractor.
CERTIFICATION AGENCY is a Third Party Inspection Agency appointed by PT. Krakatau
Engineering to ensure conformity by the Vendor with all requirements necessary to obtain
certification of the goods and/or services described herein so as to get the total facilities certified by
them.

3. CODES, STANDARD, SPECIFICATION AND PROCEDURE

The following codes, standard, specification and procedure shall be used as part of this work method:

ASTM A 36 - Carbon Structural Steel

ASTM A 307 - Carbon Steel Bolt and Stud

ASTM A 325 - Structural Bolt, Steel, Heat treated

ASTM A 123 - Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Product

ASTM A 563 - Carbon and Alloy Steel Nuts

ASTM F 436 - Hardened Steel Washers

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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

AISC, 9th Ed. - Specification for Design, Fabrication and Erection of Structural Steel for
Building.

AWS D1.1 - Structural Welding Code for Steel

JIS G 3101 - Structural Steel

4. GENERAL REQUIREMENTS
The following minimum document such as Shop Drawings, Erection Plans, Field Bolt Lists, Floor
Plate Arrangement Drawings, and any drawings shall be provided prior fabrication.

4.1 GENERAL
A. All Shop Drawings, Erection Plans, Field Bolt Lists, Floor Plate Arrangement Drawings
and other drawings shall follow the design drawings and requirements of this
specification. The drawings shall give details of each assembly, member, fixing,
fabrication procedure, surface coating/ preparation and erection.
B. Member identification marks shall be in accordance with All drawings shall be drawn to
a scale that all information and lettering is clearly legible.
C. To ensure easy reading, the minimum height of letters and figures shall be 2.5 mm.
D. The space between lines of lettering should not be less than half the character height (in
titles closer spacing may sometimes be unavoidable due to the size of letters and
restricted room).
E. Line thickness on drawings should not exceed 0.7 mm for the thickest lines and 0.2 mm
for the thinnest lines.
F. Fine detail shall be shown separately and suitable enlarged.
G. Welding symbols shall be in accordance with AWS D.1.1.
H. The size of drawing sheet shall be limited to A1 (594 mm x 841 mm) with the exception
of the following which shall be A4 (210 mm x 297 mm).

4.2 REFERENCE TO DESIGN DRAWINGS

Design drawings provide information that is required for the detailing of the structures.
Detailing on Shop Drawings, plan lists etc., shall at all times follow what is the essence of the
design drawings together with requirements herein.
Show all appropriate details on the Shop Drawings, Erection Plans, Floor Plate Arrangement
Drawings and other approved drawings to ensure accurate and timely execution of the work.
If a discrepancy on the design drawings is found, it shall be immediately informed in writing
before the preparation of Shop Drawings.
Fabricator shall not obtain dimensions from the design drawings by using a scale rule, nor
shall dimensions and information from them be ascertained by guesswork.
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

Fabricator shall ensure that he is familiar with all relative information including CONTRACTOR
standard drawings etc. If there is doubt regarding any aspect of the design drawings then he
shall inform CONTRACTOR, in writing, without delay, before preparation of Shop Drawings.

4.3 SHOP DRAWING

A. Shop drawings shall give details of each assembly, member, fixing, fabrication procedure, surface
coating/ preparation and erection.
B. Information given shall include:
1. Identification marks for members, component parts of members, and all individual
pieces.
2. Relevant dimensions of items, including cut length.
3. Locations of all steel parts by means of key plants, levels, grids, etc.
4. Type and size of all welds including groove configuration.
5. Bolt holes and full connection details.
6. Details of cuts, copes, notches and chamfers.
7. Details of camber.
8. Off-set dimensions from center of columns or center supporting beams to center of
bolt holes of supported beams.
9. Working Point (WP) to Working Point (WP) dimensions including inclinations and
angles.
10. Direction marks.
11. Surface treatment (painting) requirements.
12. Shop Bill of Material.
C. Shop Drawings shall specify all procedures necessary for shop and site assembly.
D. Workshop bolting shall be indicated on the Shop Drawings as SHOP BOLT(S),
specifying diameter, grip, order length, grade tightening procedure, and information
regarding washers.
E. Applicable welding symbols shall be used in every case and on no occasion shall they
be omitted.
F. The size of fillet weld shall be given together with the symbol.
G. Direction marks of members shall be shown on the Shop Drawings by indicating
NORTH, TOP, etc., and the approximate location on the member where it is to be
marked.
H. Corresponding Design Drawing Number and their revision numbers shall be marked on
Shop Drawings.
I. Shop Bill of Material
1. Definition
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

The Shop Bill of Material is a list of material scheduled in a manner such to clearly
identify by size and shape of each component part of each shop fabricated
structure, frame, unit, etc., and to quantity these parts in the unit specified.
It is prepared on a Shop Drawing by each Shop Drawing basis schedule covering
what is shown on each individual Shop Drawing or each inter related group of Shop
Drawings.
2. Principal Requirements
Shop Bill of Material shall be as listed below:
Identification marks for member, component parts of members, and all
individual pieces.
Size and form
All relevant dimensions
Quantities (individual and total)
Unit weight (i.e. nominal weight per meter or square meter as applicable)
Weight of individual pieces or component parts of members
Weight of each composite member (i.e. weight of a member and its component
parts to be shipped together)
Note:
The weight of each composite member shall appear as a sub total in
schedules
Total weight per each Shop Drawing
3. A separate summary sheet of the total weight of structural steel shall be prepare as
per each shop drawing.

4.4 ERECTION PLANS

Erection Plans shall give the following information:
1. Orientation
2. Principal members of the structure
3. Working Points (WP)
4. Member identification marks
5. Top of steel elevation
6. Gusset plate locations for single shear connection
7. Site welding details
8. Bolting details (Field Bolt Lists)

Erection Plans shall show clearly all the component parts, which is forming the finished
structure, to facilitate timely erection. Any special procedures necessary for field erection shall
be shown with precise instruction.
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

All necessary information and detail in plan, in elevation, and in section, plus Field Bolt Lists,
shall be shown on one drawing sheet.
Field Bolt Lists shall:
1. Give complete information required for field bolted connections to facilitate speedy
erection without error
2. Specify location, diameter, grip, order length, grade, quantity required, and washer
requirements
3. Indicate bolt location with cross-reference to Erection Plans
4. A separate summary sheet listing all of field bolts shall be prepared on a structure basis
(on A4 sheets) and shall be summarized in accordance with grade, diameter, length,
single/ double nuts, and washer requirements.

4.5 REVIEW
CONTRACTOR reserves the right to review, comment and approve all documents submitted
by the Fabricator.
CONTRACTOR approval, with or without comment of the Fabricator drawings or data, does
not relieve the Fabricator from complying with all terms, conditions, codes and standards, and
the requirements of appertaining structural steel specifications for shop fabrication and site
erection.
CONTRACTOR also reserves the right to review, comment, and re-approve drawings that
have previously been approved with or without comment, etc.
The Fabricator shall at all times check and certify with an authorized signature that his own
drawings and data which are not certified, or which are found at any time by CONTRACTOR
to be incomplete will be returned to the Fabricator for re-submission.

5. PRODUCT HANDLING

5.1 DELIVERY AND STORAGE

Deliver all materials to the job site properly and marked to identify the structure for which it is
intended. Marking shall correspond to that indicated on the Shop Drawings. Store in a manner
to maintain identification and to prevent damage.
Prepared delivery list shall showing:
A. All member identification marks and quantity
B. Quantity of fasteners, classified in accordance with designations, diameter, length, etc.
C. Other necessary information for the site erector, the company arranging site delivery,
and/ or CONTRACTOR.

5.2 FASTENER
All fasteners shall be delivered in small boxes or kegs by the fabricator and clearly marked
with labels as to the requirements for fasteners of this specification. In the event of a small
quantity of fasteners, bags with tags may be used.
Fasteners in box, keg or bag shall be identical size, length and grade of material, and shall be
of one identification code of the structure.
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

If requested, bolts, nuts and washers shall be matched and assembled in one set by the
Fabricator before delivery in boxes, kegs or bag.

5.3 REPLACEMENT
In the event of damage, immediate repairs and replacement shall be undertaken to the
approval of CONTRACTOR necessarily and at no additional cost to CONTRACTOR.

6. MATERIAL
The material shall be new and selected for the purpose for which it is intended to be used and shall
be in accordance with Structural Design Criteria For Steel Structures Specification and/or
equivalent under the CONTRACTOR approval.

6.1 SHAPE
All steels to be used shall be in correct shape without any harmful defects or considerable rust
and perfectly true to thickness.

6.2 MATERIAL INSPECTION AND MATERIAL CONTROL

For material inspection refer to Procurement and QC Inspection Procedure and for Material
control, refer to Material Control Procedure.

6.3 MATERIAL CERTIFICATES

For each batch of steel provided for the works, the manufacturers Certificate of Compliance
and Test Certificates registered bodies shall be provided, unless approved otherwise.

7. EXECUTION
Execution in this procedure covers yard or workshop fabrication of the various members,
components, frames, units, parts etc., that make up the required steel structures.

7.1 FABRICATION
A. General
The workmanship and finish shall conform to AISC and this procedure.
B. Straightening & Bending
Before marking-off, steel, which enters the shop fabrication, shall be checked for
conformity with the standards. Any bent or otherwise distorted material shall be
straightened and made true before marking-off. Steel may be repaired or corrected
subject to prior approval by CONTRACTOR.
The method of repair or correction shall not cause damage to the properties of the
material and shall be submitted to CONTRACTOR for approval. Approval will only be
given if it can be shown that the proposed repair or correction will not reduce the
properties of the steel below specified.
Straightening and bending shall be done by mechanical means at ambient temperature
and approved for the procedure proposition.
C. Marking off
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

1. The marking-off steelworks including the location of holes may be done manually
from what it shown on the Shop Drawings, or where a large number of identical
items are required, by the use of previously prepared templates.
2. The use of chisels or center punches for marking on material and those parts of the
work which are prone to defects by such action is not permitted.
D. Cutting
1. In principle, automatic or semi-automatic gas cutting machines shall be used for
cutting of steel plates. Use of manual gas cutting shall be limited and should be
accompanied by guides, etc. Shearing machine can also be used for cutting of sub-
members to be utilized with plate thickness of below 12 mm. Shearing of material
thicker than 12 mm shall not be permitted unless expressly approved.
2. Cold sawing shall be used when it is required to cut a section accurately to length
and bevel. In principle, band saw cutting machines are used for cutting shapes. On
occasions, shearing machines can be utilized for L-shapes or shapes with
thickness of below 10 mm. Re-entrant corners shall be shaped notch-free to a
radius at least 10 mm unless otherwise shown on the drawings.
3. The cut face of each member shall be perpendicular to the axis line unless
otherwise specified on the drawings.
4. The cut edges of members and of all gusset plates, cleats and other connection
fitments shall be free of gouges, burrs and other defects that would adversely affect
the serviceability of the steelwork or detract from the finished appearance. All burrs,
fins and raggedness left by sawing, punching, shearing, cropping or flame cutting
shall be removed before assembly and welding of parts.
5. Quality of gas cutting shall be as follows:

ITEMS ALLOWABLE LIMIT * CORRECTION

Notches Up to 0.04 inch (1.0 mm) deep Up to 0.08 inch (2 mm) ; G
(for main member) More than 0.08 inch (2
mm) ; W +G
Up to 0.08 inch (2.0 mm) deep Up to 0.12 inch (3 mm) ; G
(for sub member) More than 3 mm ; W + G
Surface, Roughness Below 100s (for main
members)
Below 200s (for sub members)
Note:
* Allowable limit method correction works
G = grinding; W = welding

E. Drilling
1. Drilling of members shall be drilled accurately in accordance with the marking.
2. Holes shall be made by drills but punching of holes shall only be permitted if the
plates thickness is 10 mm maximum.
3. All burrs shall be removed by grinding.
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

4. Holes for bolts shall not be more than 20 mm greater in diameter, unless otherwise
specifically required by design.
F. Holing
1. All bolt holes shall be drilled or otherwise machined perpendicular to steel surface.
Flame cut holes or burn enlarged holes are not acceptable. Burrs, fins and other
defects shall be removed.
2. Holes for pinned joints shall be bored after welding and other fabrication
procedures are complete. Pins shall be machined and fitted so that forces are
distributed evenly to the adjoining members.
3. All steels to be used shall be in correct shape without any harmful defects or
considerable rust and perfectly true to thickness.

7.2 ASSEMBLING
A. General
1. Prior to assembling, marks each part dimensions and bending degree shall be
checked with shop drawings.
2. Plate and components which are to be welded shall be assembled aligned and
retained in position for welding to ensure that the dimension and tolerance specified
are maintained during welding and that the required shape of the assembly is
obtained after welding.
3. In assembling, special care shall be taken in order to avoid misalignment in
direction of plate thickness and bending from joint part due to angular distortion.
Touch face of the part to be fillet welded shall be brought into as close contact as
practical.
4. Assembling skid shall be strong enough to remain firmed during fabrication and be
kept horizontally.
5. In case whereby the member is required to be tacked welded to the jig, it shall be
carefully gouged and finished smooth by grinding after completion of fabrication or
welding works.
B. Tack-welding
1. Tack-welds shall be done by low hydrogen electrodes with diameters 3.2 mm or 4.0
mm.
2. Tack welding shall not have short bead. The length of tack weld shall not be less
than four times (4x) the thickness of the thinner part or 50 mm which ever is smaller
for ordinary steel and 80 mm as standard practice.
3. In case any crack occurs in the part where tack welding has been applied, it shall
be gouged up to the bottom of deposited metal and re-welded.
4. Tack welding shall be applied to the reserve side of the back gouged part as a rule.
However should it not be practical for structural reasons, the alternative method
shall be carefully used in consideration that tack weld should become part of the
first pass of welds.
 Sheet 11 / 14

PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

7.3 WELDING
A. Edge Preparation
1. Edge preparation of the weld groove shall be conducted by machine cutting or
mechanically guided flame cutting. In flame cutting, the cut surface shall have a
roughness not greater than ANSI surface roughness value of 25.
2. Surfaces and edges to be welded shall be smooth, uniform, and free from fins,
tears, cracks, and other discontinuities, which would adversely affect the quality of
strength of the weld. Surfaces to be welded and surfaces adjacent to the weld shall
also be free from loose or thick scale, slag, moisture, grease, rust, paint, and
foreign material that invalidate the welding procedure qualification or procedure.

B. Weld Termination
1. Welds shall be terminated at the end of a joint in a manner that will ensure sound
welds. Whenever necessary, this shall be done by use of extension bars and runoff
tabs.
2. In open structures, extension bars and runoff tabs shall be removed, unless
otherwise directed by CONTRACTOR.
Unless directed by CONTRACTOR, extension bars and runoff tabs in shelters and
caddied structure need not be removed unless they are likely impede to
subsequent fabrication, handling and erection, or injurious to personnel.

C. Control of Distortion and Shrinkage

1. In assembling and jointing parts of a member or built-up members and in welding
reinforcing parts to members, the procedure and sequence shall be so as to
minimize distortion and shrinkage.
2. In so far as practicable, all welds shall be made in a sequence that will balance the
applied head of welding while the welding progresses.
3. Before welding commences, the fabricator shall establish a welding sequence for
members or structures, which, in conjunction with the joint welding procedures and
overall fabrication method, will produce members, or structures meeting the
requirements specified herein.
D. Execution of Welding
1. Welding electrodes shall be properly handled at all times. Electrodes which
possess defects such as peeling of coating materials, stains, degradation, humidity,
rust etc., shall be discarded. Electrodes shall be preconditioned for use in
accordance with manufacturers recommendations. CONTRACTOR reserves the
rights to reject any welding electrodes which have been incorrectly stored, handled,
or for other reasons are considered no longer suitable.
2. Back-gouging as necessary shall be made on the first layer in the groove root such
that welding defect is removed with minimum loss of sound metal. The gouging
shall be done by air carbon arc gouging or mechanical chipping.
 Sheet 12 / 14

PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

3. At corners and edges of filled weld or partial penetration weld, welding shall be
made continuously around the corner.

E. Weld Cleaning
1. In Process Cleaning
Before welding over previously deposited metal, all slag shall be removed and the
weld and adjacent base metal shall be brushed clean. This requirement shall apply
not only to successive layers but also to successive beads and the crater area
when welding is resumed after any interruption.
2. Cleaning of Completed Welds
Slag shall be removed from all completed welds. The weld and adjacent base metal
shall be cleaned by mechanical wire brushing or other approved method. Spatter
remaining after the cleaning operations shall be removed by chipping.
F. Tolerances
Workmanship tolerance in assembly of welded joints and the quality of the weld shall
satisfy the requirements of AWS D1.1.
G. Repairs
1. Before any attempt is made to straighten or correct distorted steel, Fabricator shall
submit a detailed procedure or work method to CONTRACTOR for approval.
Fabricator shall demonstrate in their procedure that the method will not reduce the
properties of the steel below those specified. Repairs shall not commence until
written approval is given by CONTRACTOR.
2. Removal of weld metal or portions of the base metal may be by machining,
grinding, chipping or air carbon arc-gouging. Flame gouging is not allowed.
Removal shall be undertaken in such a manner that the remaining weld metal or
base metal is not nicked or undercut.
3. Unacceptable portions of the weld shall be removed without substantial removal of
the base metal.
4. Additional weld metal to compensate for any deficiency in size shall be deposited
using an electrode smaller than that used for making the original weld, and not
more than 4 mm in diameter. The surfaces shall be cleaned thoroughly before
welding.
5. Overlap or excessive convexity shall be removed.
6. For excessive concavity of weld or crater, undersized welds, and undercutting,
additional weld metal shall be deposited after cleaning the surfaces.
7. For excessive weld porosity, excessive slag inclusions, incomplete fusion, and
unacceptable portions shall be removed and the area re-welded.
8. Members distorted by welding shall be straightened by mechanical means or by
carefully controlled application of a limited amount of localized heat. The
temperature of heated areas shall not exceed 650 C as measured by temperature
indicating crayon or other suitable means. Except for stresses resulting from the
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

mechanical straightening method used in conjunction with application of head, the

part to be heated for straightening shall be substantially free of stress and external
forces.

7.4 PAINTING
Painting shall be carried out in accordance with the Technical Specification for Surface
Preparation.

8. TESTING AND INSPECTION

CONTRACTOR shall be notified and shall have the opportunity if witnessing all tests including the
preparation of test pieces.

8.1 MATERIAL INSPECTION

Materials shall be verified as having met the requirement of section 1.3 above.
Test certificates shall be reviewed, and correction of material with respect to test certificates
shall be verified.

8.2 DIMENSION INSPECTION

Dimension of a structural component shall be inspected and verified as complying with the
tolerance limits specified in specification. Actual dimension of a structural component shall be
recorded.
Dimensional inspection records shall show specified dimensions, actual dimensions, errors
and specified tolerance limits to facilitate review.

8.3 WELDING INSPECTION

An independent testing laboratory acceptable to CONTRACTOR shall carry out all tests and
test records for qualification of welders.
Edge preparation and alignments of welded joint shall be inspected to ensure they comply
with the requirements of AWS D1.1.
Visual inspection of welds shall be performed to ensure that permissible levels of
imperfections of AWS D1.1.
Welds are to be checked for leg size or throat thickness as marked on drawings.

8.4 TRIAL ASSEMBLY

Structure, only if specifically be requested or indicated in the relevant drawings shall be trial
assembled and/or be erected temporarily at the shop and subjected to be inspected by
COMPANY after such assembly.

8.5 FINISH PRODUCT INSPECTION

A finished product inspection shall be carried out on the following items using the steel
material lists provided by fabricator.
- External Appearance
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PT. KRAKATAU
HSM 2 Project Doc. No. Rev.
ENGINEERING
Fabrication Method ENG-JOB-TBC-PRC-XXX 0

- Groove Dimension and Appearance for Field Welding

- Deflection to total length of member
- Dimensional tolerances and twist
- Marking for erection
- Packing for shipment
- Painting/coating quality and thickness.