00 29 July 2018 ISSUED FOR APPROVAL Gulf Steel& Engineering Shiraz.

P Ashraf Taha

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

MAIN CONTRACTOR SUBCONTRACTOR

PROJECT NAME

AL MAHA CENTER FOR CHILDREN AND YOUNG ADULTS WITHIN AL WAKRA

HOSPITAL CAMPUS

DOCUMENT TITLE

QAQC PLAN STRUCTURAL STEEL WORKS

DOCUMENT NO. REV. NO. DATE SHEET

GSE-PQP-2018-001 00 29th JULY 2018 1 OF 40
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TABLE OF CONTENTS

1.1 INTRODUCTION……………………………………………………………………………………..………….5
1.2 SCOPE………………………………………………………………………………………………….……………5
1.3 QUALITY MANAGEMENT APPROACH………………………………………………….…………….5
1.4 REFERRENCE DOCUMENT…………………………………………………………………….…………..6
1.5 ABBREVIATION…………………………………………………………………………………….……………7
1.6 QUALITY OBJECTIVES…………………………………………………………………………….………….7
1.7 QUALITY CONTROL……………………………………………………………………….……..….………..8
1.8 QUALITY ASSURANCE…………………………………………………………………….……..….……….8
2.0 QUALITY POLICY & ISO CERTIFICATES…………………………………………….……..….………..9
2.1 QUALITY POLICY………………………………………………………………………….……...……….9
2.2 ISO CERTIFICATES………………………………………………………………………….…………...10
3.0 QUALITY SYSTEM………………………………………………………………………………….……….….11
3.1 QUALITY SYSTEM………………………………………………………………………….………….…11
3.2 DEGREE OF QUALITY SYSTEM……………………………………………………….…………….11
3.3 WORKS PROCEDURE AND INSTRUCTION………………………………………….………...11
3.3.1 QUALITY PLANS…………………………………………………………………….........11
3.3.2 SUBCONTRACTORS………………………………………………………………….……12
3.4 PROJECT ORGANIZATION PLANS COMMUNICATION
AND RESPONSIBILITY……………………………………………………………………………..….13
3.4.1 ORGANIZATION AND COMMUNICATION………………………………….……13
3.4.2 RESOURCES & COMPETENCIES…………………………………………….…….….13
3.5 KEY PERSONNEL & RESPONSIBILITY………………………………………………….………….14
4.0 PROCEDURE…………………………………………….…………………………………………….…………..17
4.1 PLANNING PHASE…………………………………………….………………………………………....17
4.2 DOCUMENT CONTROL………………………………………………………………………………...18
4.3 ENGINEERING …………………………………………….………………………………………….……18
4.4 PURCHASING …………………………………………….………………………………………………..19
4.4.1 PURCHASING REQUIREMENTS WILL CONSIST OF (LPO) …………………19
4.4.2 CHECKING, TRACKING AND MATERIAL CONTROL PROCESS…………...19
4.4.3 CRITERIA FOR RE-EVALUATION……………………………………………………...20
4.5 INCOMING MATERIAL CONTROL AND INSPECTION………………………………………20

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4.5.1 MATERIAL PRELIMINARY RECEIVING…………………………………………..…20

4.5.2 RAW MATERIALS INSPECTION…………………………………………..……….….21
4.5.3 STORAGE AND ISSUE OF MATERIAL ……………………………………….……..21
4.5.4 WLDING CONSUMABLES……………………………………………………….……...22
4.5.5 FCAW/GMAW FILLER WIRES TO BE ISSUED AS REQUIRED……………..22
4.5.6 SHIELDING GAS………………………………………………………………………………23
4.5.7 CALIBRATION AND MONITORING OF EQUIPMENTS……………………….23
4.5.8 NON-CONFORMITIES (NCR) – CORRECTIVE, PREVENTIVE ………………24
4.5.9 WELDING PROCEDURES/WELDERS & WELDING OPERATORS
QUALIFICATIONS …………………………………………….……………….…………...25
4.5.10 FABRICATION ………………………………………………………………………………27
4.5.11 CUTTING AND SHAPING……………………………………………………………….27
4.5.12 FITTING …………………………………………….…………………………………………27
4.5.13 MARKING…………………………………………….………………………………………27
4.5.14 CURVING (CAMBER) AND STRAIGHTENING …………………………………28
4.5.15 WELDING …………………………………………………………………………………...28
4.5.16 CHECK VISUAL WELD QUALITY CAMBERING, CURVING AND
STRAIGHTENING …………………………………………………………………………28
4.5.1.7 FINAL DIMENSION ……………………………………………………………………..29
5.0 COMPONENTS AFTER FABICATION ……………………………………………………………………29
5.1 NON-DESCRUCTIVE EVALUATION ……………………………………………………………….30
5.2 CLEANING WORK …………………………………………………………………………….……..…..30
5.3 COATING WORK …………………………………………………………….…………………………...31
5.4 LOADING AND SHIPPING OF FABRICATED MEMBERS ……….………………………...31
5.5 PAINT TOUCH UP WORK ………………………………………………….………………………….31
5.6 FABRICATION FLOWCHART ……………………………………………….………………………..32
6.0 ERECTION ………………………………………………………………………………….………………………33
6.1 HANDLING OF MATERIALS AND FABRICATED ITEMS ON SITE…….…………………33
6.2 SCHEMATIC PRESENTATION FOR THE HANDLING OF MATERIALS IS GIVEN
BELOW ……………………………………………………………………………………………………….34
6.3 LIFTING AND PLACING ………………………………………………………………………………..35
6.4 MAINTAINING TOLERANCE …………………………………………………………………………35
6.5 FOLLOWING MAXIMUM PERMISSIBLE TOLERANCE IN ERECTED STEEL
STRUCTURE………………………………………………………………………….……………….…….36
6.6 JOINTS ………………………………………………………………………………………………..………37
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6.6.1 BOLTED CONNECTION …………………………………………………………..……..37

6.6.2 WELDING CONNECTION ………………….……………………………………..…....38

7.0 AS-BUILT DRAWINGS ………………………………………………………………………….…………....39

8.0 PROJECT HANDOVER AND FINAL INSPECTION ………………………………………….…….…39
9.0 SUMMARY ………………………………………………………………………………………………….…….39
10. PROJECT ORGANIZATION CHART …………………… ….……………………………………………40

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1.1 INTRODUCTION
1.2 SCOPE

 The Scope of the Project Quality Plan is designed to provide a common framework
for an effective execution of the structural steel, which has been manufactured,
fabricated, painted and erected by Gulf Steel Engineering for Project: “Al-Maha
Center for Children and young Adults within Al Wakra Hospital Campus” as per
specific responsibilities, work instructions and project specification quality
management system throughout the project.

 This framework is the project’s quality benchmark in order to provide high quality
products and processes by identifying the basis for reviewing and auditing of the
products and activities to verify that they comply with applicable procedures and
standards and to assure that the deliverables quality is according to the contractual
requirements emphasizing the project quality management role that governs the
decisions and instructions concerning project quality.

The PQP shall describe the means and methods for ensuring satisfactory materials and
workmanship, including the following preparation

 Procurement, maintenance
 Calibration of testing equipment and supplies needed for inspection,
measurement, and tests
 Conformance of all raw materials to project requirements.
 Handling, shipping, receiving, storing of the Raw materials
 Joint Preparation and use of welding procedure specifications (WPSs) and
control of welding consumables.
 Use of the latest approved version of shop drawings and approved
fabrication procedures
 Proper performance of non-destructive examination (NDT) by approved
third party
 Handling of non-conformance’s, including use of standard shop repair
methods and approved procedures for weld repairs.
 Shipping, installation and handing over.

1.3 QUALITY MANAGEMENT APPROACH

 Quality Management is defined as, “a subset of project management that includes the
processes required to ensure that the project will satisfy the needs for which it was
undertaken.” It consists of Quality Planning, Quality Assurance and Quality Control.

 The approach for ensuring the appropriate Quality Management conducted by the
Project Management, this includes all activities of Quality Management that determine
the quality policy, objectives, and responsibilities and implements them by means such
as quality planning, quality control, quality assurance, and quality improvements.

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 The project’s Quality Management approach adheres to and includes work activities in
support of the following quality management processes sequence:

1.4 REFERENCE DOCUMENTS:

The steel Structural work shall be performed in accordance with this procedure and the
following specifications, codes, regulations and industrial standards, which by being
referenced shall be a part of this specification.

Document Description

QCS 2014 Section 16 Qatar construction specification

BS EN ISO 15614 Structural welding code- Steel
BS 5950 Structural Use of Steelwork in Building
BS EN 10025 Specification for Sections / Plates Structural Steel
BS EN 10210 Specification for Hollow Sections Hot rolled
BS EN 10056 Structural steel equal and unequal leg angles (Part 1, 2)
BS EN 1011 Welding – Recommendations for welding on metallic materials
(Part 1, 2, 3).
BS 5135 Metal-arc Welding of Carbon and Carbon Manganese Steel
BS 729 Hot Dip Galvanized Coatings on Iron and Steel Articles
BS 3692/ BS4190 /ISO 4017 Specification for the Anchor Bolt, connection bolt
BS 3692/ ISO 4032 Specification for the Nut
BS 4320/ ISO 7089 Specification for Metal Washer
AWS D1.1 American Welding Society Standard
AISC American Institute for Steel Construction

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1.5 ABBREVATION

No Abbreviation Description
01 Client Owner

02 Contractor Hyundai Engineering & Constructions

03 GSE Gulf Steel& Engineering

04 QA Quality Assurance

05 QC Quality Control
06 WPS Welding procedure specification

07 PQR Procedure Qualification Record

08 WQT Welder Qualification Test

09 HSE Health Safety Plan

10 ITP Inspection Test Plan

11 IRE Inspection Request

12 MS Method Statement

13 PQP Project Quality Plan

14 TDS Technical Data Sheet
15 MSDS Material Safety Data Sheet

16 QCS 2014 Qatar Constriction Specification

17 BS EN ISO 15614 Structural steel welding code.

1.6 QUALITY OBJECTIVES: -

The goals of Gulf Steel Engineering, with regard to quality assurance are as follows
 The development of this document shall ensure requisite quality
management and adoption of a ‘Right First Time’ every time with ‘Zero
Defects’ culture.
 To meet the specified requirement of the client.
 To complete all the work within the agreed construction time at good
quality.
 To maintain the executed works with in the maintenance period as per
the agreed contract.
 To expand our business by offering the best in quality, cost and
program.
 GSE shall ensure that the fabrication and installation of the project shall
be able to achieve design

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 Ensure that the work shall also be governed by the main contractor
quality policy and key performance indicator.
 Ensure that the work shall also be governed by the end user policy.
 Measuring performance and continuous improvement.
 Conduct operations in conformance with all applicable environmental laws
and regulations of the jurisdictions in which we do business.
 To ensure APPROVED status is achieved for the first time submission of
documents.
1.7 Quality Control
Quality Control (QC) personnel role is performing inspection accompanied by
documentation of the work product deliverables throughout the life of the project as stated
in the project ITP meanwhile the material receiving, fabrication, to the product finalization
the ITP and the detailed work procedures with its acceptance criteria; has to be subjected
to the GSE QA/QC and Client approval ensuring that; all these starting documents
completely cover and capable to verify compliance with the contractual/specification
requirements.
QC must assure the:

 Compliance of Fabrication progress to the schedule and target

 Compliance of quality inspection progress to the schedule and target.
 Quality documents implementation and status.
 Project Material status with the presence of acceptable material
certificates.
 Issuance of Raw material and/or fabrication NCRs status and required
client approvals.
 Insure all inspection activates at site (insulation, alignment, bolt tightening,
painting and fire proof) comply with approval and specifications.

1.8 Quality Assurance

Quality Assurance is an important task throughout the fabrication process, in order to

monitor and report on the achievements of the project objectives.
This means that the project main outputs must be in accordance with contractual
requirements, they must be in compliance with the specification and they must adhere to
broadly acceptable quality standards.

This implies that:

 Conducting quality audits meanwhile the fabrication process

 Perform an investigation towards the causes of any customer complaint(s)
or any non-conformity case implementing a corrective action to prevent
reoccurrence
 Following-up the corrective actions full implementations of any aroused
nonconformities
 Establishing a system for the implementation of the fabrication
documentations identifying their fulfillment responsibilities.
 Intensive review of the primitive and final fabrication documentation.
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2. QUALITY POLICY& ISO CERTIFICATE.

2.1 Quality Policy

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2.2 ISO 9001 Certificate

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UPDATING OF QUALITY PLAN

This project quality plan can be updated and or revised to suit each particular contract and or
quality assurance system to be followed. Any amendment or updating to this plan shall be
discussed among the project quality team of client and project management / quality team to
consider the reviewing parties, approval of the amendment shall be made by our client and
revision of the quality plan will be prepared. Each amendment will be serially numbered as
next latest revision, entered on the amendment sheet and distributed to all holders of the plan.
Each amendment will outline the new procedures to be followed for that particular task and to
be discussed by the QA/QC Engineer among project construction team.
Each amendment shall be recorded in the amendment file, which shall be distributed to all
holders of the quality plan.

3.0 QUALITY SYSTEM

3.1 QUALITY SYSTEM

GSE Company Pledge of Quality declares our commitment: "GSE employees will always
respect our customers' viewpoints in striving to deliver product quality and customer service
that exceed their expectations." To this end, GSE promotes continuous, decisive efforts to
enhance product quality and to reinforce its quality management system.by specific
requirement of QCS 2014 and project Specification.

3.2 DEGREE OF QUALITY SYSTEM

In order to efficiently and effectively perform their jobs, employees must have a clear
understanding of their roles and responsibilities within their organization and the existing
documented quality management system and how their efforts contribute to the achievement
of the goals and quality objectives. The Projects (and /or Contracts) vary in size and complexity
so; this does not imply higher or lower standards of workmanship but indicates the amount of
supervision, inspection, testing and documentation to ensure the specification is met.

To exert effectiveness, client shall ensure that design and development for the related works
is properly planned, with its input and output properly reviewed and any changes shall be fully
validated to conform to the project requirement. GSE on its part shall be fully responsible for
the success of the work by having its project personnel perform the works in accordance with
the approved.

3.3 WORKS PROCEDURE AND INSTRUCTIONS

All items in relation to this document will be controlled by works procedures and method
statements separate work procedures or instructions will be written where applicable to suit
specific tasks or project, in addition to the already established project documents.
Method statement submitted for this project shall be documented, where procedures are
included as appendices to this quality plan.

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3.3.1 QUALITY PLANS

Quality plans are used on each project to implement the quality system and include the
following:

 Identification of client specific requirements

 Identification of critical service or process characteristics to meet client
requirements
 Preparation of control plans and associated process monitors
 Identification and acquisition of resources
 Control of critical information and to preclude unintended use
 Definition and management of key organizational interfaces
 Verification of the compatibility of new services with process and test capabilities
 Development of new monitoring and assessment capabilities
 Definition of acceptance criteria for key critical service or process characteristics
 Consideration of operations safety during the Construction Phase of projects.
 The identification and preparation of quality records.
 Preparation of contingency plans to protect our client's and our business interests
 Monitoring of the work environment
 Maintenance of the cleanliness and organization in GSE premises and operations
sites.

3.3.2 SUB CONTRACTORS

GSE investigates for specialized sub-contractors or suppliers according to required

material; considering list of suppliers and sub-contractors’ records and new jobs awarded
to subcontractors. The acceptance criteria to choose the subcontractors and suppliers is
as the following.

 To meet with project specification and client requirement.

 To provide the materials within the agreed time at good quality.
 Supply the material with required certification MTC.
 Accepted to return back the rejected materials by Q.C department if not comply with
project spec.
 All structural steel material received from subcontractor should be approved by
Contractor and Client prior to procurement.

Where GSE used subcontractors they are to comply with the GSE quality system and
quality work procedures unless they can demonstrate that their quality system is
acceptable to GSE as per project requirements and project spec. The Quality Assurance
Department, who directly reports, and is not conditioned by production or delivery
problems, is responsible for monitoring, verifying and documenting the correct
implementation of the project requirement.

Gulf Steel & Engineering shall cooperate and coordinate with his Client in all matters
relating to the quality control procedures and all personnel directly involved in this project
shall be continuously kept informed of contract requirement and work procedures.

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3.4 PROJECT ORGANIZATION PLAN, COMMUNICATION and RESPONSIBILITY.

3.4.1 ORGANIZATION & COMMUNICATION

EMPLOYER

EMPLOYER
ASSISTANT

Consultant EMPLOYEE PROFESSIONAL QDVC

GULF STEEL AND ENGINEERING

QRGANIZATION CHART

3.4.2 RESOURCES & COMPETENCES

Plan of Resources (Competence, training and awareness)

GSE ensure that the qualification requirements (such as education, skills, training, experience)
for each job are identified, determined and documented in job descriptions. Training is
provided to employees or other actions are taken in order to meet defined qualification
requirements. The effectiveness of provided training or of related actions is evaluated. Any
candidates that will qualify will be called on for technical interviews

GSE ensure that designated person assigned for a specific task has the ability to perform the
job efficiently, has related knowledge, abilities and qualities that can be used as standard
against which the job and performance is measured in accordance with his designation.

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Authorized Representative

The GSE designated QA/QC Engineer / Quality Inspector shall be the person in charge for all
related Gulf Steel & Eng. site QA/QC activities and inspection as per the approved ITP.

Execution of the works on site as per the project specification and quality standards shall be
the responsible of Gulf Steel & Engineering constriction team under the direct supervision of
client.

3.5 KEY PERSONS & RESPONSIBILITY

Operation Manager:

Overall responsibility of project and each department.

Project Manager:

 Ordering of materials, equipment’s for at the site as per requirement.

 Reviews overall project planning, examines implementation with subordinates and
submits weekly progress reports to the Operation Manager
 Will have the responsibility of the project for execution, quality and safety; maintain
the planning, progress and coordination with client /engineer.
 Coordinating all activities of a project such as technical and contractual
correspondence, plan, implementation of method, schedule of work etc., with
various parties involved, from the installation up to completion.
 Oversee the quality& quantity of work and subcontractor productivity, attend
progress meetings with client and inform the project status to the management
periodically.
 Ensures 100% customer/consumer satisfaction by applying all customers’
requirements
 Ensures that the handing over formalities of projects is done after final verification
and are in accordance with company quality assurance policy.

Production Manager:

 Implement and maintain a successful completion of work.

 Ensure that this method statement is being implemented correctly.
 Ensure that sufficient resources are allocated to enable full compliance with this
document.
 Ensure that all works are being carried out as per the project specifications and
approved drawings.
 To keep all his personnel fully aware of the quality control principles and he shall
support to the project quality control department.
 Follow up and update the construction planning.
 Control of requisition, provisions of construction materials.
 Control of technical issues –review of technical submissions.
 Interpret contract drawings, specifications, and being familiar with all provisions of
the contract and any revisions or amendments.
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 Responsibility for the quality of work carried out by all personnel under his control
including sub- contractors.
 Records and control of production documentation.
 Ensure that staff under his control areas are experienced and trained in their
relevant disciplines.
 Drawing modification and technical query shall be initiated by Production Manager.

Planning Engineer

 Prepares and submits master program of the project in consultation with Project
Manager.
 Prepares and submits Planning Data’s to be incorporated to the submittal of Project
Progress Report (weekly/ monthly) in coordination with Project Manager and Site
Quantity Surveyor and submit same to the Consultant / Client for Approval.
 Submits planning report such as preparation of manpower requirements for the
project, preparation of material procurement report in accordance with approved
program.
 Prepare and update project schedule based on the contract.
 Coordinate with Project Manager the effective implementation and monitoring of
Look Ahead-Schedule including the project actual accomplishments.
 Participate in project meetings and discussions with the Client as required.
 Reports to the Project Manager the status of project progress against the plan
schedule and provides corrective actions necessary if the planned schedule is not
achieved.

QA/QC Manager:

 QA/QC Manager shall coordinate with Client on all stages of work as per the ITP
and the implementation of QCP
 Maintain all quality records
 Conduct inspection and monitor the required tests
 Determine and report any NCR and recommend corrective actions.
 Ensure that all personnel should be fully aware with the all quality requirements and
Application for all quality documents as relevant to their discipline
 Ensure appropriate supervision control of all work activities so that all quality related
operations are effectively covered.
 Rising of relevant Request for Inspection and transmission to Quality Department
before the scheduled inspection or test.

QA/QC Engineer / QC inspector

Assigned to assure and to plan that all the clients' requirements and workshop as well as the
site quality activities are fulfilled through the QC personnel according to the approved quality
control plan through:

 Reviews QC project ITPs, Method statement, NDT, and Painting Procedures.

 Initiates, recommends or provides solutions to quality problems
 Control and review of Project Raw material and/or fabrication NCRs
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 Apply different quality control procedures and activities according to the job.
 Control the delivery of products before releasing the factory.
 Identify and Organize the QC site activities from receiving the fabricated materials
till the erection and installation

QA Engineer

Assigned to assure that the project processes are complied with Gulf Steel & Engineering
quality management system and verifies the proper execution of the project quality activities
through:

 Ensures the QA processes and procedures adequately control project quality.

 Promptly reports results of audits to the project task leader.
 Verify the compliance with the approved project ITPs and procedures.
 Control and review of Project NCRs; till close it out and follow the full implementation
of the corrective actions.
 Assign QA personnel for the quality monitoring and evaluation of quality
accomplishments at site.
 Verify the Review of the final documentation” Final Book” before hand over to the
Client.

Document Controller (DC)

 The Document Controller is responsible for the receipt, control and distribution, and
revision control of all technical documents and drawings pertaining to project.
 Coordinate with the Contractor’s DC in controlling and preparing the Documents
 Coordinate with contractor’s QA to ensure the proper filing system is implemented.

Welding Inspector:

 To be fully aware of the Day to day Inspection program for structural steel works in
advance so that he can raise the RFI in a timely manner.
 To attend all inspection / Witness points in a timely manner and records the results
of his inspections on the appropriate forms.
 Completion and filling of all inspection records under his responsibility and reporting
to QA/QC Manager.

Supervisor / Foreman:

 Assist the QA/QC Coordinator to execute and maintain overall quality of the work
on daily basis
 Be directly in charge in the execution of activities
 Ensure also that the working area is safe for the workers and equipment’s

HSE Manager/HSE Officer:

 Ensure that tool box talks are conducted as per HSE plan
 Assist in the implementation of this Project Quality Plan.
 Provide required training for the site personnel involved
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 Ensure availability of required tools to maintain a safe work place

 Ensure compliance with procedure respect to equipment’s and related certifications
and permit.

Installation Manager/Site Engineers

 Responsible for achieving installation goals specific to their location for all GSE on
site or off site projects
 Provides overall direction of Field Service coordinator in support of departmental
objectives
 Reviews performance; addressing escalated issues and resolving problems
concerning installation
 Assists General Manager and project manager by providing technical clarifications
concerning installation
 Complies with management reporting and communications as requested
 Ensuring that the equipment & instruments used for construction and day-to-day
temporary activities are of high quality and complies with company, industry and
government authority standards.
 Ensures that all resources like manpower, machineries, materials and equipment
are made available for undisturbed site activities and are allocated wisely.
 Carries out supervisory responsibilities in accordance with the organization's
policies and applicable laws.
 Works with multiple departments regarding installation related project.

4.0 PROCEDURES:

4.1 Planning Phase

 Contract Quality Review

The review of contract requirements containing specific quality requirements, against requirements
are the responsibility of the designated project manager.

 Quality Planning Procedure

A project specific Quality Plan will be developed by GSE Project Manager, based on contract,
engineering drawing and specification requirements, to assist in planning, receiving, inspection and
in process inspections.

 Quality Planning Documentation

Manufacturing and quality operation procedures and work instructions shall be created prior to
manufacturing. Aconex is used to provide list of Documents that have been uploaded as per Contract
requirements.

 Kick-off Meeting

Prior to Fabrication meeting per project shall be convened to ensure all departments are
knowledgeable of contract requirements.

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 Key Performance Indicator(KPI’s)

End of project we sort and inventory of goals accomplished and lessons learned from the completed
projects. Now is the time to carve out a few hours with your QA/ QC and Development teams to review
the achievements.

4.2 Document Control

Drawing and specification used to control the fabrication, processing, Erection and site work of
contract deliverable items will be controlled and documented in accordance with the following, and
entered Drawing Index and Status Log:

 Distribution of drawings
Ensuring that the distribution of revised drawings is established according to an identified
system.
a. Any revision in the drawings (Technical office/Client/Factory) will be identified using
the Revision Card.
b. Release of shop drawings & Revision status will be identified using Index of drawing
by the Technical Office Document control.
c. Planning Dept. is responsible of distributing the updated drawings, attachments
inside the workshop and sites
d. Make sure that the old revision is taken before submitting the new ones & stamped
by OBSOLETE stamp.

 Quality Assurance records

Records that documentary evidence of quality shall be specified prepared and maintained.
Records shall be legible, identifiable and retrievable. Records shall be protected against
damage, deterioration or loss. Requirements and responsibilities for record transmittal,
retention, distribution, maintenance and disposition shall be pre-established and
documented.

4.3 Engineering

 Detailing shall be responsible for producing all shop and erection drawings as required by
the contract. It shall be the drafting department responsibility to produce copies of shop
drawings for Approval. Upon receipt of contract drawings Detailing shall record date of
arrival, contractor’s name, job title, and number of addendum’s received. Drawings will
clearly note any special instructions. Detailing shall be done per contract documents.
Welding symbols per project specification.

 Upon completion of shop drawings, the number of copies required by the specifications
will be printed and forwarded to the Client for review and Approval. When approved shop
drawings are received back from client, Detailing will check Notes. They will review the
drawings and make any corrections as noted by the client. When completed, the drawings
will be passed to the workshop for fabrication and procurement.

 The design drawings for shop use with the intent of supplementing the AISC standard
manual. The detailer shall be familiar with the QCS 2014, BS 5950, steel detailing
specifications, shop practice and field erection procedures.
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 Training of Detailing personnel is under direct supervision of the Engineering department

head.
o Drawing should show followings
o All drawings must show Material Specification
o Drawings must show customer, job name & item description
o Purchasing will then be able to track material for specific jobs as to mill test
reports (main material, weld electrodes, bolts, etc.)
o Drawing must show any specification that is standard. The below are the normal
standards for steel material, grade of the materials as per the design drawings.

a) Steel sections and Plates: BS EN 10025

b) Hollow sections Hot rolled: BS EN 10210
c) Hollow sections cold Formed: BS EN 10219
d) Tubes and pipes: BS EN 10210
e) Anchor Bolts, Nuts & Washers: DIN 975/BS 3692
f) Connection Bolts, Nuts & Washers: BS 3692 grade 8.8, BS 4320
g) ISO 4017 grade 8.8/ISO 4032 CL 8 /ISO 7089
h) Paint: According to MAR and Project specification
i) Welding Procedures: As per BS EN ISO 15614
j) Process FCAW: AWS D1.1
k) Process SMAW: AWS D1.1

4.4 Purchasing

 Purchasing responsibility:
Project management is responsible for the purchasing of the materials, services and
processing of contract deliverable items. Purchasing is accomplished by the project
manager. It is the policy that all material and services required for the project to
confirm the contract requirement.

4.4.1 Purchasing requirements will consist of (LPO): -

a) Grade of Material
b) Specification
c) Quantities
d) Sizes
e) Identification marking requirements
f) Certification requirements
g) All structural steel material should be approved by Contractor and Client prior to
procurement.

4.4.2 Checking, tracking and material control process:

a) Receive copies of the LPO/MPO from Purchase Clerk. (Material Controller)

b) Receive materials and arrange to offload with specified marking on the materials
related to Job # for identification (Material Controller)
c) Prepare SRV and submit to Procurement supervisor (Material Controller)

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d) Material controller notify all concerned departments for the shipment arrival
supported by its packing list and purchase order (If Applicable); and confirming
the requested starting date of inspection with the responsible department.
e) Material Controller makes a preliminary receiving of the incoming materials
comparing the coming packing list and purchase order (If applicable) against the
actual incoming materials to detect any discrepancy may be occurred using the
Over/Short/Damage Report.
f) QC is responsible for the inspection of all materials that may affect the product
conformity. In case of detected non-conformity, apply the control of non-
conformity procedure.

4.4.3 Criteria for Re-Evaluation:

The process is utilized for evaluating the Suppliers based on their ability to supply the right
product at the right time in conformity with the specifications and compliance of all
documentation process as per the rules to optimize the total quality of the Procurement
Planning process;

a) Record the defective or the damaged supply if any against each LPO/MPO/ to find
out the cost of defective supply
b) Quality of work and additional another features.
c) Time schedule commitment,
d) Project Specification commitment
e) Environmental and Safety rules commitment
f) Manpower/equipment performance
g) Delay (processing time -dispatch date).

4.5 Incoming Materials Control and Inspection

4.5.1 Material Preliminary Receiving:

a) Material controller notify all concerned departments for the shipment arrival
supported by its packing list and purchase order; and confirming the requested
starting date of inspection with the responsible department.

b) Material Controller makes a preliminary receiving of the incoming materials

comparing the coming packing list and purchase order (If applicable) against the
actual incoming materials to detect any discrepancy may be occurred using the
Over/Short/Damage Report.

c) Material controller submits a copy of the Over/Short/Damage Report to the

Procurement Head who will send it after review to the QC Head, Planning Head
and Project Manager.

d) The Project Manager will contact the Client for any detected discrepancy; if the
materials supplied by the Client.

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4.5.2 Raw Materials Inspection:

a) QC is responsible for the inspection of all materials that may affect the product
conformity
b) QC Inspector makes his final inspection for the incoming Materials on the Material
Receiving Report (MRIR) form in according to the Project Inspection and Test Plan
(ITP), Project specifications, approved drawings, Project related Codes, Standards
and Project approved Quality procedures.
c) After inspection the QC Inspector Obtaining the QC Head approval on the material
receiving report; then retain it with its related support documents; like mill/test
certificates (If required).
d) Receiving inspection will be performed by GSE designated Quality Control person.
e) All Structural Steel material arriving at workshop shall be inspected prior to use and
check for the following during material inspection:
• Material Test Certificate(MTC)
• Damage & Corrosion
• Supplier recommended preservation / protection
• Quantity against shipping document and PO data
• Identification & Marking of Material such as Grade, size item number, heat
number & Tag number.
• Inspection Release Notice shall be attach.
• Dimension of received materials
f) After GSE QC inspector carried out the inspection on receiving materials and
approved on it.
g) If required QC raise inspection request to (TPI) to check all materials, then after
approved.
h) If required QC raise RFI to client QC to check all materials also as per approved
ITP.
4.5.3 Storage and Issue of Materials:
a) Material Controller is responsible for the storage process of the incoming materials,
giving the storage instructions to the store keeper and the arrangement of the
materials according to the steps of production/erection or approved project
planning.
b) Raw material shall be stored in a designated area under supervisor. Material will
be identified to provide GSE Job Number for traceability
c) Upon release of materials by QC, the material controller is responsible for handing
over of the requested materials from storage yard to the fabrication/erection
engineer at the working area; using Material Issue Voucher to assuring that; their
requested materials have been properly released.
d) Material Controller shall perform regularly balance of materials to illustrate his
control on the receipt and dispatch of materials from the material storage area on
the Material Weekly Status Report.
e) Planning Head use the material weekly status report for the preparation of project
weekly progress in accordance with approved project plan and send to client.

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4.5.4 Welding Consumables:

 Incoming electrodes shall be inspected by the QC inspector against the following items:

 Types and diameter against the purchase order and the accompanied Mill
certificates.
 All damaged packages shall be rejected and returned back to the supplier.
 One package from each shipment shall be randomly chosen to weld a test
specimen to check:
 Fusion of completed weld (visually).
 Appearance of completed welding consumable (visually):
 Welding consumables shall be unloaded to an area segregated from other certified
stock. The storekeeper shall receive deliveries of welding consumables checking
brand. AWS class, Size, Quantity and packing is as per the purchase order and
delivery document and that certification is provided. Packing shall be examined for
damage, which shall be reported to the QC department to determine the effective
of damage and advise disposition.
 Welding consumable certification shall be checked by the QC to determine that it
is as per the request order and specification. return of the certificate to store man
shall release for storage
 Bundle of electrodes shall be carried out as per the manufacturer instruction.
Tagging of the electrodes is not required as electrodes are clearly marked by the
manufacturers and they are separated in the consumable store based on their
trade name, AWS number and size.
 Storage of the consumables shall be in designated area, which shall be used for
the storing of the welding consumables. The area shall be dry and protected
according to manufacturer recommendations.
 The consumable shall be segregated by type (eg: SMAW electrode, GMAW wire,
SAW Flux, SAW wire, SS electrode…. etc), AWS class, Brand, size, batch number
and shall be maintained in original shipping bundles.
 Consumables shall be stacked with adequate tonnage at stacking heights per
manufacturer recommendations. Consumables shall not be stored on floor.
 Welding consumables are issued as per the requirement at shop by the welding
Foreman.

4.5.5 FCAW / GMAW filler wires to be issued as required;

SMAW Electrodes:

 Electrodes for SMAW shall conform to the requirements of the AWSA

5.1(Specification for Carbon Steel Electrodes for SMAW).
 Immediately after opening the sealed package, Electrodes shall be stored in ovens
held at a temperature.
 All Electrodes having Low-Hydrogen coverings conforming to AWS A 5.1 shall be
baked for at least 2 hours between 260 C and 430 C.

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 All Electrodes shall be placed in a suitable oven at a temperature. Final baking time
shall start after the oven reaches final baking temperature.
 Welding Consumables that have been removed from the original package shall be
protected and stored that the welding properties are not affected as per
manufacturer’s recommendation.
 Electrodes of different sizes and qualities must be kept in clearly identified
compartments of oven.
 Once baking is completed, follow the first–in-first-out system for issue while the
electrodes are in holding ovens.
 A logbook shall be maintained to ensure that electrodes are dried as per
requirements.

4.5.6 Shielding Gas

Gasses or gas mixture(s) for shielding in GMAW is stored in proper manner and easy access
to welders. For GMAW process the gas mixture. The use of Carbon Dioxide is common in
many welding applications 99.8% Co2. The reference Standard are AWS A5.32M/A5.32:2011
& ISO 14175:2008.

4.5.7 CALIBRATION AND MONITORING OF EQUIPMENT’S:

Monitoring and measuring equipment are used and controlled in a manner that ensures
continuing suitability; this includes ensuring that the environmental conditions are suitable
for the calibration, inspections, measurements and tests being carried out.
We also define the processes employed for the on-going calibration, control and
maintenance of monitoring and measuring equipment including their identification,
location, frequency/method of checks, uses/acceptance criteria and the action to be taken
when results are unsatisfactory.

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 All monitoring and measuring equipment that can affect work quality are identified and
calibrated at prescribed intervals against certified equipment having a known valid
relationship to internationally or nationally known standards. Where no such standards
exist, the basis used for calibration is documented. The external laboratories used for
inspection, test or calibration services are selected, qualified.

 When monitoring and measuring equipment are found to be out of calibration (or when
calibration status is not known), they are adjusted or re-adjusted as necessary and the
validity of previous measuring results is documented; actions taken are documented,
including appropriate corrective actions to remedy the situation and preclude its
recurrence.

 All measuring and monitoring equipment’s and inspection tools shall have valid
calibration during inspection as per the project specification and the calibration records
will be maintained through calibration log register as client requirement.

 All welding machines and inspection equipment’s are periodically calibrated (Yearly).
Individual equipment’s have serial number for identification

 All calibrated equipment should be registered and maintained in the GSE template.

4.5.8 NON CONFORMITIES (NCR) – CORRECTIVE, PREVENTIVE

Purpose:
To ensure that all non‐conformances are identified and recorded, and that the appropriate
corrective action is taken to rectify all identified non‐conformances, preventing their
reoccurrence in the future.
Responsibility.

 All members of staff are responsible for notifying the Quality Manager of any
identified non‐conformances.
 A copy of the NCR is forwarded to all responsible managers that are involved in
the scope of works related to the NCR, for information and action.
 The Quality Manager is responsible for the completion of Non‐Conformance
Reports and for determining and implementing corrective action.
 Once the corrective action has been completed the Quality Manager is to
undertake a verification check to ensure that corrective action has been effective.
Minor & Major Nonconformity

 Minor nonconformity – Any nonconformity which does not adversely affect the
performance, durability, interchangeability, reliability, maintainability, effective use
or operation, weight or appearance (where a factor), health or safety of a product.
Multiple minor nonconformities when considered collectively may raise the
category to a major or critical nonconformity.
 Major nonconformity – Any nonconformity other than critical, which may result in
failure or materially reduce the usability of the product for the intended purpose
(i.e. effective use or operation, weight or appearance (where a factor), health or

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safety) and which cannot be completely eliminated by rework or reduced to a minor

nonconformity by an approved repair.

Repair Non-Conformity

 Establish and maintain an effective system for controlling nonconforming material,

including procedures for identification, isolation, and disposition.
 Establish standard shop repair methods. Standard repair welding procedures must be
preapproved by the client.
 Describe the equipment, inspections, reports, and systems necessary to segregate
materials requiring corrective work.
 Follow these steps when a problem is identified that will require a repair approved by
the Engineer:
 Determine the root cause for the case
 NCR Investigation for Corrective and Preventive Action purpose.
 Responsible Manager must investigate the root causes that initially caused the NCR.
The identification of root causes is very important because it may also lead to
Corrective Actions or Improvement Actions
 Initiate appropriate action to prevent additional deficiencies.
 Submit a written proposal to the Engineer documenting the situation, suggesting
corrective actions for repairs or replacement, and, if applicable, recommending
alternate methods for subsequent production to avoid further defects.
 Provide the NCR with copies of appropriate correspondence.
 Be prepared to provide support information if requested by the client.

The corrective actions for NCRs shall be discussed and agreed with the contractor within 14
Days. The NCRs shall be closed within 30 days or the closing date shall be agreed with the
contractor.

Controlling Nonconformities

All relevant documentation to this procedure such as NCRs and registers. If the NCR cannot
close within 30 days, GSE shall propose the corrective action and the new target closing date
shall be discussed with contractor and the updated register with the new target date shall be
submitted to the contractor.

4.5.9 Welding Procedures/Welders & welding Operators qualifications

Preparation of Procedures
Approved written welding procedures shall be available in accordance with Project
specification. QC Engineer select the required materials to prepare for the welding
procedures and tested in accordance with BS EN 288 Part 3 with Third party.
Procedures and tests shall be approved by an independent Inspection Authority. Also
Welding Procedure sheets shall be made available to the welder prior to the
commencement of the work and shall be available to the Engineer and Inspection
Authority on request. See Approved WPS.

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Qualification of welders:
 The name of the department or position responsible for administering and maintaining
documentation on the qualification test program.
 The extent to which independent testing laboratories will be employed in qualification.
 The extent to which the QC department will be involved in qualification.
 QC Engineer selecting and testing qualification plates, authentication of test reports,
and the disposition of specimens.
 Appropriate forms and records
 Master list of qualified welders, welding operators, and tack welders
 Renew the welder certificates every six months by evaluating the welder performance
by supervision Engineer.
 The certification shall remain valid providing it complies with the conditions for re-
approval of certification specified in BS EN 287 Part 1.
 Welder testing shall be witnessed and certificates endorsed by an independent
Inspection Authority (Supervision Engineer)
 Qualification actions taken when new welder are joined in workshop.
 Make all welder qualification test results available for the Client’s review.
 Prior to start any welding activity Welding Procedure Specification (WPS) and Welder
shall be approved by client.

4.5.10 FABRICATION:
The purpose of this chapter is to emphasize the quality measures of the fabrication process
throughout the execution of the project from the prefabrication stage till the sand blasting
and painting before the release to site.

Preparation of Material

 Identification and marking of materials

 Quality of cut and sheared edges

Plate quality, with notation of surface and internal defects and repair

 NDT requirements and acceptance criteria for repairs

 Dimensional accuracy of component parts, whether fabricated or pre manufactured.

4.5.11 CUTTING AND SHAPING

Cutting and shaping of steel may be carried out by shearing, sawing, laser cutting or
machine flame cutting, except that where machine flame cutting is impractical, hand flame
cutting may be used.
Punching is permitted without the conditions of this Part, provided that the holes are
punched at least 2 mm less in diameter than the required size and the hole is reamed to
the full diameter after assembly.

4.5.12 Fitting
Built up Columns steel structural shall be assembled in jigs or on suitable surface plates
with proper layouts as per the drawing. Column bottom plate will be kept at bottom and
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side’s two vertical plates will be fit up with the bottom plate by means of Butt weld joint.
Stiffener plates will be provided at least every 1 meter to avoid the distortion and to
maintain the built up box column sizes & shape. The top plate shall be fit-up with this two
plates and complete the fit-up of Built up box column by tack weld. After completion of
full built up box column joint fit-up, S/C GSE QC Inspector will check the fit- up and
release for welding. Such as,

 Dimensional accuracy and fit of all components

 Specified tolerance of members prior to welding
 “Mill to bear” and “tight fit” conditions

4.5.13 Marking
 The marking of pieces, as well as the position of such marking on the piece, to be
carried out in accordance with the erection drawing applicable and include the
information stated therein. when the drawing does not mention the marking position
on the piece, this will be obviated by issuing a document and / or sketch drawn up at
the time of marking providing sufficient information for the retrieval of the marking
itself.
 All parts shall be marked with a punch so that every piece has the assembling
references.
 The retrieval of the marking on large size pieces shall be made in the site without
need of handling.

4.5.14 Curving (Camber) and Straightening.

Curving or straightening components during fabrication, shall be performed by one of the
following methods:
 Mechanical means, taking care to minimize indentations, or change of cross-section.
 The local application of heat, ensuring that the temperature of the metal is carefully
controlled, and does not exceed 650oC
 The induction bending process where the procedure used includes careful
temperature control; after curving or straightening, welds within the area of curving or
straightening shall be visually inspected.
 Welds which are to be subject to non-destructive examination shall have these tests
carried out after curving or straightening.

4.5.15 Welding
General Requirement of Visual Inspection

Weld visual inspection shall be carried by fabrication engineers or certified welding inspector
as per approved standards for external defects like, surface porosity, under cut, excess
penetration, and overlap, lack of penetration or incomplete fusion and fillet sizes.

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 Cleanliness (absence or condition of unacceptable mill scale, rust, or contaminants)

 Joint preparation
 Properly cleaned tack welds of suitable quality and size
 Use of approved welding procedures
 Weld quality and soundness requirements as per Welding Code
 Welders qualified for process and position to be welded the items.
 Interpass cleaning and temperature
 Weld back gouging and cleaning
 Fillet weld size, placement and profile
 Groove weld reinforcement
 Grinding or finishing of welds

4.5.16 Check Visual weld quality Cambering, Curving and Straightening

 Adequate blocking elevations and intervals
 Following Engineer-approved calculations for locations of applied external forces or
restraints, when required by the contract
 Size and locations of heating patterns
 Maximum temperatures and proper temperature monitoring
 Controlled cooling

4.5.17 Final dimensions

The fabricated steel structural shall be inspected in accordance with respective approved
fabrication drawing and specification. Overall length, orientation, diagonal measurement and
all other dimension shall be verified and recorded. If dimensions are not with required
tolerance the member shall be corrected prior to further process.

All dimensions shall be recorded in approved format. 100% visual inspection shall be carried
out for external defects. If required client QA/QC shall conduct the final inspection and
review all inspection reports and prepared as inspection and test plan (ITP).

The dimensional tolerances shall be as per QCS 2014.

Shop Assembly of Main Members

1. Dimensional accuracy of each piece (deviation from specified length, camber, sweep)
2. Individual member distortion, local and overall (twist, sweep, out-of-flatness of flange
or web)
3. Clearance or bearing fit of adjacent members in assembly
4. Assembly blocking dimensions and curve and camber offsets and elevations
5. Splice plate and secured fill plate dimensions and fit (gaps, non-parallel)
6. Bolt hole accuracy, including adequate edge distances
7. Bolt hole condition, including shape and squareness to faying surface
8. Match-marking of splice plates and correct location of all piece marks
9. Removal of drilling burrs
10. Preparation and documentation of “as built” shop assembly report

Fabrication tolerance is as follows as per QCS 2014.

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5.0 TOLERANCE OF COMPONENTS AFTER FABRICATION

SN
TYPE
.No ALLOWED DEVIATION

1 Length
(Length after cutting)

2 Curved or Cambered

3 Position of Fittings
(Critical joints only)

4 Position of Holes

5 Squareness of Section

6 Flanges

Plate Distortion
7

8 Web Distortion

Cross Section at Bearings

9
Squareness of flanges to web

10 Web Stiffeners After Welding

11 Web Stiffeners After welding

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5.1 Non-destructive Evaluation

General requirement of Magnetic Particle Testing (MT)

Magnetic particle testing procedure shall be in accordance with approved Standard. The
Evaluation of indication and the acceptance criteria shall be in accordance with approved
standards. Independent testing authority MPI reports shall be obtained for fillet welds.

General requirement of ultrasonic test/examination (UT):

The ultrasonic testing of plates for lamination shall be in accordance with SA 435 and UT of
Butt joint shall be in accordance with approved standards. Independent testing authority UT
reports shall be obtained for all butt joints.

 Review and approve the qualification documentation of those performing NDT. NDT
personnel Qualified to a minimum of ASNT Level – II.
 Witness NDT, review the test results, and verify that reports are complete and legible.
 Calibration of Equipment to be maintained and it should be available during request.

5.2 Cleaning Work

 Proper solvent cleaning to remove surface contamination prior to mechanical cleaning

 Blast media gradation and cleanliness
 Verification and documentation of required surface cleanliness and profile
 Checking the compressed air system for contaminants, especially if used to remove
shot
 Proper functioning of automated blasting equipment
 Treatment of material defects (scabs, fins, slivers) exposed by blasting, including re-
blasting if necessary after repairs
 Proper corner and edge treatment as required for coating system
5.3 Coating work:
Inspection often begins with a pre-job conference at which the ground rules are set. The
inspector is responsible for witnessing, verifying, inspecting and documenting the work at
various points. The following points will be reviewed along with the appropriate instruments
used for each.

 Pre-Surface Preparation Inspection

 Measurement of Ambient Conditions
 Evaluation of Compressor (Air Cleanliness) and Surface Preparation Equipment
 Determination of Surface Preparation Cleanliness and Profile
 Inspection of Application Equipment
 Witnessing Coating Mixing
 Inspecting Coating Application
 Determination of Wet Film Thickness
 Determination of Dry Film Thickness
 Evaluating Cleanliness between Coats

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All results of any inspection shall be thoroughly documented in writing to verify that the
specified requirements have been met. Future maintenance or the removal of a failed coating
system may be dependent on the factual reporting of every phase of the work.

5.4 Loading and shipping of fabricated members

 Written acknowledgement of Qc acceptance before loading
 Proper packing and Loading of materials in to truck
 Repair of all areas where shop protective coating has been damaged
 Visual inspection of all loaded members.

5.5 Paint touch up work.

The fabrication at shop should be so planned that units to be handled weigh nearly the same.
The erection drawing should reach the site of construction well in advance to plan the erection
sequence and material handling. Erection should be carried out with the help of maximum
possible mechanization by using tower crane or mobile cranes.

5.6 Fabrication Flow chart

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6.0 ERECTION

The purpose of this chapter is to emphasize the quality measures and surveys of the erection
and installation processes at site throughout the execution of the project from the receiving of the
fabricated material at site till the erection and installation. GSE scope at site

 Erection according to the system package installation.

 Installation according to drawing and plan.
 Site mobilization (containers) and demobilization.
 Unloading, storing and handling.
 Providing of qualified stuff for site and project management.
 Providing of qualified indirect and direct manpower.
 Providing of the necessary erection consumables, auxiliary material, and tools with its
calibration certificates.
 Aligning and permanently connecting the members by bolting or welding
 Connecting bracing to the steel structural skeleton.
 Providing the necessary erection mobile cranes if required.
 Painting touch up for damaged steel areas.

6.1 Handling of Materials and Fabricated Items on Site:

The painting structural after fabrication shall be protected from further damage during
transportation. The materials will be loaded on the trailers using timber supports and
separators and secured properly to prevent any damage to the material while transportation
to site.

Fabrication items will be delivered loose. Minor fabrication items, which are not likely to be
subject to permanent deformation during handling operation (i.e. bracing etc.) may be bundled
or hoped. Small items (i.e. bolts, loose, cleats etc.) will be packed in crates / drums or loaded
on pallets.

The erection process requires considerable planning in terms of material delivery, material
handling, member assembly and member connection. Proper planning of material delivery
would minimize storage requirement and additional handling from the site storage, particularly
heavy items. Erection of structural steel work could be made safe and accurate if temporary
support, false work, staging etc. are erected. Before erection the fabricated materials should
be verified at site with respect to mark numbers, key plan and shipping list. The structural
components received for erection should be stacked in such a way that erection sequence is
not affected due to improper storing. Care also should be taken so that steel structural
components should not come in contact with earth or accumulated water. Stacking of the
structures should be done in such a way that, erection marks and mark numbers on the
components are visible easily and handling does not become difficult. From the earlier
discussion it should emphasized that safe transportation of fabricated items to the site, their
proper storage and subsequent handling are the pivotal processes for the success of
fabrication of structural steel work.

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6.2 A schematic presentation for the handling of materials is given below

In principle there are 3 storages for the materials

Arrival storage Area: For the materials when they are off loaded from the trucks and registered.
The materials will be inspected at this location and certificates of release at the factory will be
reviewed. Materials that need repair work will be tagged and repaired at this location.
Main storage Area: For the materials which has its QC acceptance and considered ready for
erection.
Quarantine storage: Where the quarantined materials will be kept. Issue NCR for these
materials and send it back to workshop for rectification.
It is planned to provide materials in site required for enough days’ erection according to the
project erection plan. Proper contacts will be made with the factory to ensure proper flow of
materials to avoid shortage of materials or excessive storage of materials over the capacity of
storage area.

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6.3 Lifting & Placing

 A variety of methods can be employed for the erection of a structure. Normally, the
selection of the method is influenced by the type of the structure, site conditions,
equipment, quality of skilled labor, etc. available to the erector. However, regardless
of the method adopted the main aim during erection is the safety and preservation of
the stability of the structure at all times. Most structures which collapse do so during
erection and these failures are very often due to a lack of understanding on someone's
part of what another has assumed about the erection procedure. Hence, it is
emphasized that as far as strength and stability of the components during erection are
concerned, they must satisfy the provision of QCS section 16 and AISC standards. For
the guidance on general fabrication and erection of structural steel work, QCS section
16 must be followed. Before the commencement of the erection, all the erection
equipment tools, shackles, ropes etc. should be tested for their load carrying capacity.
Such tests if needed may be repeated at intermediate stages also.

 Thus quality control must start from the setting out of the foundations and the holding
down bolts. This operation is often done at a stage when site conditions are disorderly
and most untidy and the environment appears to be incongruous to accuracy.
However, inaccuracies in marking the center lines and the levels of foundations
allowed at this stage are likely to cause misfit in the connections and misalignment of
the structure leading to secondary stresses in the members. In such areas corrective
measure must be taken by way of locally modifying some of the components so as to
eliminate the mismatch

Bracings

 During the entire erection period, the steelwork should be securely bolted or otherwise
fastened and braced to take care of the stresses from erection equipment or the loads
carried during erection. In addition to this, adequate provisions to resist lateral forces
and wind loads during erection should also be made according to local conditions.
Normally bracings are built into all types of structures to give them a capability to with
stand horizontal forces produced by wind, temperature and the movements of crane
and other plant in and on the building. Bracings can be permanent or temporary.

 Temporary bracings required at some stages of the work must have properly designed
connections and should be specifically referred to in the erection method statement.

The decision on sequence of erection such as which member should be erected first for
providing initial stability to the structure or whether temporary bracings should be used for
this purpose should be taken at an early stage of planning of the erection process.

6.4 Maintaining tolerances

The best method of erecting a structure within the acceptable tolerance limits is to make sure
that accuracy is achieved from the very beginning of the job

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6.5 Following Maximum permissible tolerance in erected steel structures

Sr. TYPE ALLOWED DEVIATION

No
1 Foundation Level Deviation from
exact level

2 Vertical Wall
Deviation from exact position at
steelwork support point

3 Pre-set Foundation Bolt or Bolt

Groups when Prepared for
Adjustment Deviation from the
exact location and level and
minimum movement in pocket
4 Pre-set Foundation Bolt or Bolt
Groups when Not Prepared for
Adjustment Deviation from the
exact location level and protrusion

5 Position at Base of First Column

Erected Deviation of section
centerline from the specified
position

6 Overall Plan Dimensions Deviation True overall dimension “L”

in length or width L ˂ 30 meters, Δ = 20 mm
L ˃30 meters, Δ = 20 mm +
0.25 (L - 30) mm
where L is in meters

7 Single Storey Columns Plumb  = ± H/600 or 5 mm

Deviation of top relative to base, whichever is greater
excluding portal frame columns, on Max = ± 25 mm
main axes.

8 Multi-storey Columns Plumb h = h/600 or 3 mm

Deviation in each storey and whichever is greater
maximum deviation relative to base  H = 50 mm maximum

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9 Alignment of Adjacent Perimeter critical face of columns

Columns
Deviation relative to next column
on a line parallel to the grid line
when measured at base or splice
level. Δ = 10 mm
10 Floor Beams Level
Deviation from specified level at
supporting stanchion.

11 Floor Beams Level at Each End of

Same Beam
Deviation is level.

12 Floor Beams Level of Adjacent

Beams within distance of 5 meters
Deviation from relative horizontal
levels (measured on centerline of
top flange)

13 Crane Gantry Columns Plumb

Deviation of cap relative to base.

14 Crane Gantries Gauge of Rail

Tracks
Deviation from true gauge

6.6 Joints:
Most steel structures are fabricated by either bolting or welding in the shop and bolting or
welding in the field. Durability of a structure largely depends on the quality of the joints made
at site.
6.6.1 Bolted connections:
 Should be ensure that all parts intended to be bolted together should be in
contact over the whole surface and the surfaces should be thoroughly cleaned
and painted with specified primer paint and the two matching plates or sections
secured together while the paint is still wet by service bolts. After erection, the
joint should be made by filling not less than 50% of the holes with bolts.
 The service bolts are to be tightened. The holes that need enlargement to admit
the bolts should be carefully examined the extent of the inaccuracy and the effect
on the soundness of the structure. Such holes must not be formed by gas cutting
process.

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 The bolts contact surfaces the material surfaces should be absolutely free from
grease, lubricant, dust, rust etc. and shall be thoroughly cleaned before
assembling. The nuts should be pre tensioned by a torque–wrench or by the turn
of the nut method with the help of pneumatic tools. In the case of connections
such as base plate they must be aligned and levelled using wedges/ shims and
subsequently filled by grouting.

6.6.2 Welding connection:

The components should be securely held in position to ensure alignment, camber

etc., before welding is commenced. It is desirable to use wooden rams and mallet
to force the members in position so as to protect steelwork from injury and shock. It
should also be ensured that the bolts project through the nut by at least one thread.
In the case of field assembly by welding almost all the precautions needed for shop
welding may be followed. In the case of High Strength

7.0 As-built drawings:

Revised set of drawing will submit by a GSE upon completion of a project or a particular job. They
reflect all changes made in the specifications and working drawings during the construction
process, and show the exact dimensions, geometry, and location of all elements of the work
completed under the contract. Also called record drawings or just as-built.

8.0 Project Handover and Final Inspection

After completion of final alignment inspection and bolt tightness verification of the erected
structures, RFI will be raised for final inspection to the client.
All the stage wise inspection will be carried out as per Approved ITP. Erection group will perform
survey works to ensure that erected works are within tolerances specified in project specifications.
Grouting under base plate will be allowed only after erecting main elements; fully tightened their
connections and ensuring that tolerances in verticality and alignment is within acceptable range.

Final inspection will be carried out with concerned parties, documentation will submit for the
handover.

9.0 SUMMARY
This PQP explains the importance of fabrication and erection in structural steelwork is underlined.
The various tasks involved in fabrication are discussed. The joints, which are important
components in structural steelwork, are explained, with a special emphasis on welded joints.
Some aspects of erection of steel structures are also presented.

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10.0 Project Organization Chart

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