Clause No.

Project Specification Requirements FME Response

3.3 Fabrication
3.3.1 General
Steel work shall be fabricated in accordance with relevant section of BS EN 1993
except as modified herein.
Exposed cut edges of steelwork shall be rounded off by grinding. Ends of
members bearing in compression shall be machined so that the loads are
transmitted over the entire area of contact.
Plates and rolled sections required to be cut to exact lengths shall be
accurately cold sawn or machined. Hot sawing or machine gas cutting will be
permitted for the ends of beams and other parts in compression. Complied
Burrs left by the cold or hot saw shall be removed and gas cuts shall be
dressed free from oxidized metal to a neat and workmanlike finish.
The ends of the members shall be prepared in accordance with
the requirements and the maximum gap allowable between ends
will be 2 mm.
All holes shall be drilled.
3.3.2 Steel Surface Condition

The surface condition of steel for fabrication shall be in accordance with the
following standards:
• Steel surface when used not be more heavily pitted or rusted than Grade C
of BS 7079;
• Surface defects in hot rolled sections, plates, wide flats , round and
square bars revealed during surface preparation which are not in Complied
accordance with the requirements of BS EN 10163 for quality of
finished steel, shall be rectified accordingly;

• Surface defects in hot rolled hollow sections revealed during surface

preparation which are not in accordance with the requirements of BS
EN 10210-1 shall be rectified accordingly.

3.3.3 Workshop Assembly

 Fabrication must be carried out on a flat and level surface.
During workshop assembly the drifting of misaligned bolt holes is not permitted.
Critical field splices and joints must be mated in the shop on completion of
fabrication to ensure satisfactory fit when installed.
3.4 Tolerances
The fabrication tolerance shall be in accordance with BS EN 1090-2.
Weld tolerances shall be in accordance with BS EN 1011.
Erection tolerances shall be in accordance with BS EN 1090-2 and, where
relevant, shall also comply with BS EN 1993-6.
Holding down bolts in foundations shall be in accordance with BS 7419
with regards to tolerances and geometry.
Unless specified otherwise, the top of steel beams shall be within plus or
minus 5 mm from the elevation given on the working drawing.
The CONTRACTOR must provide all necessary personnel, equipment and
instruments necessary to fabricate the steelwork to the design dimensions
and tolerances.
All instruments used for the fabrication and checking of tolerances must
have current valid calibration certificates.Measurements of length must be
checked with standard steel measuring tape or band corrected to a
standard temperature of 25 degrees Celsius.
Monitoring of dimensions must be carried out during fabrication of individual
members,and before fit up of sections and sub-assemblies for conformance with
the dimensions and tolerances. FME scope is aluminum handrails, MS ladder
All beams with a natural camber within the straightness tolerance must be hand grip which complies the requirement.
fabricated and erected with the camber up.
Allowance must be made during fabrication for any change in dimensions which
may result from the erection procedure (including sag due to self-weight).
Where no appropriate tolerance is stated in this Specification, in the reference
Standards, or in the Drawings, the CONTRACTOR may assume the tolerance
to be plus/minus 2mm.
Member dimensions must be measured for conformance when all
fabrication and heating operations are completed and the member has
cooled to a uniform temperature prior to protective treatment.
3.5 Protective Treatment of Steel
3.5.1 General
 The work covered in this Section of the Specification is for the protection
against corrosion of all the structural steelwork.
All paints shall be from an approved manufacturer. The fullest possible
use shall be made of the Technical Services of the manufacturer
concerned.
Unless o t h e r w i s e n o t e d in the Specification , the color shall be Complied
to the approval of the EMPLOYER 'S REPRESENTATIVE .
The CONTRACTOR shall exercise the maximum care in handling,
transportation and erection of protected steelwork so that damage to the
coating may at all times be avoided.The use of properly assigned slings and
soft non- adherent packs shall be used throughout.
All protective treatments shall be inspected by an independent testing
authority approved by the EMPLOYER’S REPRESENTATIVE.

3.5.2 Protective Treatments

The CONTRACTOR shall provide the protective System is to be applied shall be approved by the
EMPLOYER’S REPRESENTATIVE before the work commences and shall be of such design and Painting requirements are complied.
construction that the specified conditions of temperature and cleanliness are maintained
throughout the Contractor period.
3.5.2.3 Metal Coatings
Where metal coatings are required for threaded fasteners and not
otherwise covered in the Specification, the following standards shall
apply:

• BS EN ISO 17668- Zinc diffusion coatings on ferrous products.

Sherardizing.Specification NA
• BS 7371 - Coatings on metal fasteners.This Standard shall
cover the electroplating of components up to and including 36
mm in diameter. The minimum thickness of coating shall be 5
microns.

Where nuts and bolts are to be metal coated, the attention is drawn
to the additional clearances required on screw threads as shown in
BS EN ISO 17668.
3.5.3 Surface Preparation
3.5.3.1 General
The CONTRACTOR shall carefully inspect and prepare all surfaces
to the approval of the EMPLOYER,S REPRESENTATIVE .
Surfaces of steelwork or metalwork that have been previously primed are
to be examined to ensure that they have been properly prepared before
priming and that the primer is of a suitable type, firmly adhering and
in good condition. If the condition of the surfaces or of the primer is
unsatisfactory and if the surfaces of any small items remain un-primed,
then the surfaces are to be thoroughly cleaned by mechanical chipping
or wire brushing to remove all defective primer and all rust and loose
scale back to the bare metal. If necessary, the primer shall be stripped
off completely. The surfaces are then to be primed immediately with the
appropriate primer.
If the condition of the surfaces and the primer is satisfactory then the
surfaces are to be thoroughly cleaned to remove all dirt, grease, etc., Complied
any metal exposed as a result of damage to the primer is to be wire
brushed and scraped to remove rust and primed immediately with the
appropriate primer.
Surfaces that have been galvanized are to be thoroughly cleaned to
remove all dirt, grease, etc. and then primed with a primer suitable for this
type of surface.
After preparation, the required protective treatment shall be applied.
The CONTRACTOR shall examine all surfaces prepared by others and if
the working surfaces or conditions are in any way unsuitable he shall
advise the EMPLOYER 'S REPRESENTATIVE immediately in
writing .The CONTRACTOR shall keep all working surfaces clean and
properly brushed off as the work proceeds.
3.5.3.2 Treatment of edges and corners
All edges and corners are to be smoothed by grinding to give a minimum radius All edges are smoothened by grinding, Sharp
of 2mm. edges are completely removed.
3.5.3.3 Blast Cleaning
All steelwork to be blast cleaned shall be treated in accordance with
relevant provisions of BS 7079, BS EN 8501 to BS EN 8504
"Preparation of steel substrates before application of paints and related
 products", Grade Sa 2 using automatic impeller machine blasting or
manual blasting as appropriate.
The maximum grade of abrasive permitted shall be as specified in the
above British Standards Non-metallic abrasives will only be permitted
for use with portable equipment where agreed with the EMPLOYER’S
REPRESENTATIVE.
The abrasive used for blasting shall be free from contamination and any recovered
material shall be cleaned to the satisfaction of the EMPLOYER'S
REPRESENTATIVE before reuse. The maximum amplitude peak to trough of Complied
the blast cleaned surface shall not exceed 100 micron.
A sample blast-cleaned panel measuring not less than 150 x 150 x 6 mm
adequately protected by sealed transparent wrapping, shall be submitted to the
EMPLOYER'S REPRESENTATIVE for approval before any work is commenced.
The approved sample shall be retained by the EMPLOYER'S
REPRESENTATIVE for comparison with prepared steelwork.
3.5.3.4 Hand Cleaning
All steelwork to be manually cleaned, by grinding disc, power wire
brush, chopping hammers, of needle guns shall be treated in Complied.
accordance with BS 7079, BS EN 8501 to BS EN 8504, Grade St 2.
3.5.3.5 Pickling
All steelwork to be galvanized shall be
pickled in diluted hydrochloric acid. Galvanizer procedure shall be submitted.

3.5.3.6 Storage of Steel and Fabricated Steelwork

Care shall be taken during loading, unloading, stacking and erection of any painted
steelwork to minimize damage to the protection system. All slings, ropes and
chains used to handle the steelwork shall be protected with rubber sheaths or
similar. The CONTRACTOR shall make good to the approval of the
EMPLOYER'S REPRESENTATIVE all paint work damaged during fabrication,
transport, assembly and erection. All the painted materials are handled with
Unless otherwise described in the Contract, exposure times for blast cleaned
care. Plastic sheets and wood to be used for
or coated surfaces other than at joints shall not be longer than those in the
handling. Blast cleaned items coated within
table below. "Outside" refers to any area outside a fully enclosed workshop.
4 hrs.
 The exposure times tabulated refer to any part of the surface cleaned in accordance
with Clause 3.5.3.
Table 3-1: Maximum exposure times for blast cleaned or coated surfaces
3.5.4 Paint Application
3.5.4.1 General
All brushes, tools, pots, kettles, etc., used in
carrying out the work shall be clean. They shall
be thoroughly Cleaned before being used for a
different type or class of paint. The use of lead Complied.
paints shall not be allowed in any case.

3.5.4.2 Paint Preparation

All paint shall be prepared and applied strictly in accordance with the
manufacturer’s instructions. All painting shall be carried out by skilled and
experienced painters under constant supervision of competent qualified staff.
Paint shall be thoroughly stirred when the containers are opened and when fresh
supplies are being transferred to paint pots. All paints shall be strained free from
skins, etc. Paint shall be supplied from the CONTRACTOR's paint store to the
painters ready for application. Complied
Two pack or any similar chemically cured type paint shall not be used after the
expiration of the 'pot life' stipulated by the manufacturer and such paints shall not
be mixed with fresh paints.

3.5.4.3 Application
Paints shall not be applied when the ambient temperature or the relative humidity
falls outside the limits recommended by the manufacturer, nor shall such paints be
applied when the temperature is likely to fall below the specified minimum during
the curing period.
Paints shall not be applied externally during rain, fog or mist, or where the amount
of moisture on the surface, or that likely to be caused by subsequent condensation,
may have a harmful effect. Complied
All shop painting shall be carried out in a fully enclosed workshop unless otherwise
agreed by the EMPLOYER 'S REPRESENTATIVE. Steelwork shall not be moved
outside the fully enclosed workshop until the shop protective treatment is complete.
Unless otherwise described in the Specification, a coat of paint shall be applied by
 one of the following methods:
Brush;
Roller supplemented by brush where necessary;
Air pressure spraying;

Airless spraying.

The method of application shall conform to the paint manufacturer's specification

Spray-painting will not be allowed where the soiling of adjacent surfaces is likely to
occur, unless these surfaces are adequately protected, and neither will spray-paint
ing be allowed in the case of paints containing lead.

3.5.4.4 Stripe Coating

Stripe coating shall be applied in areas which are not easily accessible. The stripe
coating areas shall be approved by the EMPLOYER 'S REPRESENTATIVE.
The stripe coat sequence can be either of the following:

Surface preparation , stripe coat, full coat ;

This sequence can be used when a large substrate area has been
Prepared and leaving the substrate exposed for a long time while doing stripe
coating could lead..U, surface deterioration. It is important that special attention is
paid to edges, openings, rear sides of stiffeners, scallops etc. and to apply a stripe Stripe coat shall be applied in inaccessible
coat to these areas where the spray fan may not reach or deposit an even film. areas.
When applying a stripe coat to bare metal a stiff, round stripe coating brush shall
be used to ensure surface wetting and filling of pits in the surface.

If applying the stripe coat after a full primer coat has been applied, the stripe coat
can be applied by either brush or by airless spray using a tip with a narrow spray
fan. Stripe coating shall be of a different colour to the main primer coat and the
topcoat colour and shall be applied in an even film thickness, avoiding excessive
brush marks in order to avoid entrapped air. Care should be taken to avoid
excessive film thickness. Additional attention shall be paid to pot life during
 application of stripe coats.

Two stripe coats shall be applied unless otherwise approved by the EMPLOYER'S
REPRESENTATIVE.

3.5.4.5 High Strength Friction Grip (HSFG) Bolted Joints

The interfaces of all HSFG bolted joints shall be cleaned as specified, left unpainted
masked off to protect them until the joint is bolted up. Blast primer or metal spray
as appropriate shall be taken 1Omm to 20mm inside the perimeter of the joint area.
Subsequent paint coats shall be stopped off progressively at intervals of 75mm
from the bolted joint. Before the joint is made the facing surfaces shall be lightly N /A
hand wire-brushed to give a clean surface free of corrosion products and any
foreign matter. Immediately after the joint has been made the primed steelwork
shall be hand wire-brushed and the specified painting systems completed.

3.5.4.6 Other Bolted Joints.

For shop joints the Blast primer shall be applied to parent and joint material.
The joint shall be assembled immediately after the first undercoat of the
painting system has been applied to the parent and contact surfaces. Complied
For site joints all surfaces, excepting those of fasteners, shall receive in the
shop the paint system which is applied to the parent surfaces.

3.5.4.7 Welded Joints.

Welds and surfaces which have been affected by welding shall receive the
preparation and protective systems which are applied to the parent surfaces.
Complied
3.5.4.8 Treatment of Completed Joints
Within 14 days of the joints having been made and passed by the
EMPLOYER'S REPRESENTATIVE·the parent And joint materials, exposed
parts of bolts, nuts and washers, weld and weld affected areas shall be NA
prepared and painted
All bolted joints shall be sealed against the ingress of moisture. Before painting
 commences, and subject to the approval of the EMPLOYER'S
REPRESENTATIVE, gaps at joints shall be plugged with approved filler. The
perimeter of all joints shall be sealed with subsequent coats of paint.
3.5.5 Storage of Paint

Paints shall be delivered in sealed containers bearing the manufacturer's name

and labelled to show the color the specification with which the paint complies
and whether for a priming coat, an undercoat or a finishing coat
No Materials of any description shall be added to the contents of the containers
except in strict accordance with the manufacturer's instructions and paints of
different types or of different manufacturers shall not be mixed together
Each batch shall be dated on delivery and shall be used strictly in order of
delivery. Paint not used within the 'shelf life' period specified on the containers Complied
or within 18 months of the date of manufacture (whichever is the lesser), shall
be replaced.

Paint shall be stored in sealed containers in a store where it will not be exposed
to extremes of temperature. The temperature of the store shall be kept between
4° C and 27° C unless the storage conditions recommended by the
manufacturer allow temperatures outside this range. Any special storage
conditions recommended by the manufacturer shall be observed.

3.5.6 Handling
All due care shall be taken by the CONTRACTOR and his employees in the
handling of all materials and equipment for painting, and the correct disposal
of all waste materials to prevent danger from fire, explosion or toxic fumes
being experienced by any person on the site. A high standard of personal Complied
hygiene shall be practiced by all operatives including the use of protective
clothing, gloves, masks and barrier creams to prevent the risks of dermatitis or
other complaints from occurring.
3.5.7 Repairs
Where the surface preparation or coating systems do not meet the standards
set out in the Specification, the EMPLOYER'S REPRESENTATIVE must be
advised immediately, and approved repairs must be carried out.
Any repair procedure is to be approved by the EMPLOYER'S
REPRESENTATIVE prior to being utilized.
Surfaces where the paint coating has been damaged or marked in any way
must be touched up or repainted in accordance with the paint manufacturer's
recommendations. Before application of any further coats, all defects to Complied
previous coats must be repaired.

Spray painting on Site is only to take place when the

CONTRACTOR has taken precautions to avoid overspray
hazards to personnel or other plant. The CONTRACTOR must
use brush application where such hazards are otherwise
unavoidable.
3.5.7.1 Repair to Damage Coatings not Exposing the steel Surface
For areas which are defective but do not expose the steel
surface, the surface to be recoated must be thoroughly washed
clean with fresh water prior to mechanically abrading the area
and surrounds with at least 36 grit abrasive paper, followed by
removal of any residual contaminants by dry compressed air or Complied
hand wiping with clean dry rags An overlap of at least 50 mm of
sound paint must be feathered around the damage area.
Multiple coats of the epoxy top coating must then be applied to
achieve the specified minimum dry film thickness over the
complete area including a minimum overlap of 50 mm over
sound paintwork
3.5.7.2 Repair to Damage Coatings Exposing the steel Surface
For coating damage exposing the steel surface, where no
contamination has occurred, the surface to be recoated must be
thoroughly washed clean with fresh water prior to mechanically
abrading the area and surrounds with at least 36 grit abrasive
paper, followed by removal of any residual contaminants by dry
compressed air or hand wiping with clean dry rags. An overlap Complied
of at least 50 mm of sound paint must be feathered around the
damage area.
The full approved coating system must be applied as per the
initial application to achieve a minimum specified dry film
 thickness over the complete area including a minimum overlap
of 50 mm over sound paintwork.

Where site welding or contamination has occurred, the

damaged section must be cleaned by grit blasting to BS 7079
and BS EN 8501 to BS EN 8504, Grade Sa 2%. Where grit blast
preparation is not practical, damaged paintwork must be
prepared by minimum power wire brush to the relevant
Standards at Grade Sa 2%, followed by abrasive paper to
provide a surface profile with overlap of at least 50 mm of sound
paint.
3.5.8 Sampling and Tasting
Samples for testing may be taken both from the sealed
container and from the work men’s kettles on the work. Any
work coated with material, the samples from which prove
unsatisfactory, shall be cleaned off and re-executed, and work Complied
on which the pain is found to be unduly thin shall be repainted,
all to the satisfaction of the EMPLOYER’S REPRESENTATIVE
and at the CONTRACTOR’s own expense.
3.6 Factory Acceptance, Inspection and Testing.
3.6.1 Inspection and Testing Plan (ITP)

All inspection and testing required by this specification and

relevant British Standards must be performed.
An ITP must be submitted to the EMPLOYER'S
REPRESENTATIVE for approval at least 14 days before the
start of fabrication. The ITP must describe the inspections, tests
and verifications for the works required, identify the mandatory
hold and witness points and describe the sequence of work
activities. Inspection and testing must comply with Quality
Assurance requirements.
The minimum acceptance and documentation requirements in
the ITP are:
• 100% visual check on materials and copies of steel manufacturers
certificates and mill test reports;
• 100% check on dimensions;
• 100% visual check on all welds;
• 100% visual check on surface treatment;
• Signed off inspection check for each item by CONTRACTOR's inspector;
• Non-destructive testing of material and welds as required by this
 Specification ;
• Coating checks as required by this Specification; Complied
• Completion report before shipping.
• Provision of welder’s, welding supervisor’s, and welding inspector’s
certificates prior to welding.
Any subsequent amendments to the ITP must be submitted for
review and approval by the EMPLOYER’S REPRESENTATIVE
prior to being implemented.
All ITP inspection activities must be performed by personnel
who are qualified and certified by a reputed organization and
shall be approved by the EMPLOYER 'S REPRESENTATIVE.
All NDT for which the CONTRACTOR is responsible must
be performed by an independent testing authority approved
by the EMPLOYER’S Certified by a reputed
REPRESENTATIVE. All NDT operators must be certified by a
reputed organization and are subject to EMPLOYER'S
REPRESENTATIVE's approval.
A copy of all documentation, certificates, and test results
collected under the ITP must be provided to the EMPLOYER'S
REPRESENTATIVE. Copies of these must be retained by the
CONTRACTOR until the Defects Liability period has expired.
The CONTRACTOR must allow and facilitate the examination
of such results by the EMPLOYER'S REPRESENTATIVE.
3.6.1.1 Material Testing Requirements in the ITP.
Prior to fabrication, all plates with a thickness greater than or
equal to 23 mm must be ultrasonically tested along all cut lines
where welding will be carried out. Continuous ultrasonic testing
must be used to establish that the plates are free from
laminations.
The method of testing must be in accordance with BS EN 10160
"Ultrasonic Testing of Steel Flat Product of Thickness Equal or NA
Greater Than 6 mm (Reflection Method)".
All tolerance requirements in this Specification, on the
Drawings, and in referenced British Standards, must be
measured and documented as being met on all members
fabricated. Dimension and tolerance checks must occur
Before and after any coating is applied.
3.6.1.2 Weld Inspection and Testing Requirements in the ITP

Unless otherwise ordered by the EMPLOYER'S REPRESENTATIVE tests

shall be carried out in accordance with the weld testing schedule given NA
below in Table 3-2: Welds Testing Schedule
 1. For tests on butt welds the percentages of examination refer to the
total numbers of butt welds.
2. For tests on fillet welds the percentages of examination refer to total
length of fillet weld.
3. The percentage of examination shall be increased to 100% (at
the EMPLOYER'S REPRESENTATIVE's discretion should a
negative result of visual inspection or non-destructive testing
indicate that a lapse of quality may have occurred in specific
joints.

Where the extent of inspection called for is less than 100% the location
of test sections shall be agreed with the EMPLOYER'S
REPRESENTATIVE.

Test certificates and additional results must be presented to the

EMPLOYER'S REPRESENTATIVE as they become available.
Non-destructive testing must be performed as necessary to qualify
welding procedures and to ensure that those procedures are adequately
maintained throughout the works.

In addition to the testing schedule

presented in Table 3-2: Welds Testing
Schedule:
Non-destructive testing may be performed by an independent testing
authority appointed by the EMPLOYER'S REPRESENTATIVE. The
CONTRACTOR must make the fabricated steelworks available in a
position and orientation suitable for testing, and must provide all
assistance and facilities necessary to the EMPLOYER 'S
REPRESENTATIVE's appointed testing authority to perform the non-
destructive testing.
If in the opinion of the EMPLOYER'S REPRESENTATIVE the welding
is defective, the CONTRACTOR must carry out additional weld testing
on two similar connections to demonstrate adequate welding quality.
The repair procedure for failed welds must be submitted to the
EMPLOYER'S REPRESENTATIVE for review and approval.
3.6.1.3 Coating Testing in the ITP
The ITP must include all inspection and documentation requirements
set out in Specification for protective coating systems. This includes
testing and minimum requirements for the preparation and coating of all
steel surfaces. All results must be documented and within 3 days of
completion of paintwork, the CONTRACTOR must forward to the
EMPLOYER'S REPRESENTATIVE two copies of the coating system
COMPLIED
inspection and test reports.
For galvanized steel surfaces, the ITP must also include all inspection
and documentation requirements set out in the Specification or relevant
Standards for hot-dip galvanizing.
3.6.2 Additional Material Testing
If requested by EMPLOYER’S REPRESENTATIVE, the
CONTRACTOR may be required to prepare and submit for testing,
specimens of material intended to be used for the primary steel
NA
members. The cost of such testing shall be met by the CONTRACTOR.
3.7 Packing and Delivery
3.7.1 General
All steelwork must be handled and stored without deformation, damage,
or overstressing. It must be stored at least 200 mm clear of the ground
on timber bearers in such a manner so as to avoid collection of water on
the steel All steelwork must be stored under cover or covered to protect
it from the weather.
Steelwork must be delivered to the site in discrete package to a program
so that erection may proceed in a logical sequence.
Steelwork dismantled for transport must be adequately hard stamped
with marking to facilitate reassembly on site COMPLIED
Prepared and/or painted surfaces must be protected during handling by
the use of a suitable packaging material such as felt or rubber, between
lifting tackle and the item. All machined surfaces must be protected by
a suitable rust inhibitor and hessian and timber sheeting.
Projections from steelwork, such as lugs and splice plates, which may
suffer damage during transport, must be protected with timber packing
pieces
 Adequate in-transit dunnage and packing must be provided to prevent
damage to surfaces and/or finish of the material. Particular attention
must be paid to protection of materials against damage by ropes and/or
chains.
Containers or bags of bolts, nuts, washers and other fixing devices must
be safely packed in steel drums or solid timber cases which must be
marked to identify the contents. Other small loose pieces must be
securely bundled and tagged. Damaged or corroded bolts must not be
used. Each bag or container must be clearly marked with the appropriate
information, such as bolt size and length.
Light slender members, small items and handrails must be bundled
together with steel straps for transport on pallets. Small parts must be
placed in sealed drums or cases.
3.7.2 Packing for Transport
Parts not completely assembled in the shop must be secured to prevent
damage during transport. Loose fittings must be wired to the appropriate
steel members in such a way as to not interfere with supplemental
COMPLIED
surface treatment or transportation considerations. Each item must be
marked in accordance with the marking plan.

3.7.3 Damaged Materials

Damaged materials for components must be replaced.
Care must be taken during delivery, offloading, stacking and erection,
so that workshop applied protective coating are not damaged. NA
Damaged paint areas must be made good by the CONTRACTOR to a
uniform colour and quality consistent with the specified coating.
3.8 Erection of Steelwork
3.8.1 General
Erection shall be carried out in accordance with BS EN 1090-2
The CONTRACTOR shall provide a method statement and ITP for the
erection of steelwork to the EMPLOYER’S REPRESENTATIVE for
approval at least 14 days prior to proposed commencement of erection.
NA
Erection marks shall be stamped or painted on all members in a manner
approved by the EMPLOYER'S REPRESENTATIVE.
 The CONTRACTOR shall provide and be responsible for all necessary
lifting tackle and gear, adequate lifting beams and points for the erection
of the works.
The structures shall be designed for the erection loads to which they will
be subjected.
The CONTRACTOR shall provide access holes as required for plant
erection.
Erection shall be carried ut in a safe manner by suitably qualified and
experienced ENGINEERs, foremen and steel erection gangs.
Adequate provision for erection stresses shall be made and for sufficient
temporary bracing to keep the structure plumb and in true alignment
until completion of erection.

The CONTRACTOR shall be responsible for the stability of the

structure at all stages during erection and shall provide and remove
on completion any temporary bracing, guys and the like required.
Bolted connections must not be left to "weather" for any period of time
before final tightening.
3.9 Stainless steelwork
Materials and Workmanship
Stainless steelwork shall comply with BS EN 10088. Stainless steel
grades shall be in accordance to Table 3-3 unless otherwise approved
by the EMPLOYER'S REPRESENTATIVE
Table 3-3: Stainless Steel Grades
If stainless steel elements are to be welded, stainless steel shall be NA
Grade 316L or equivalent
Equipment used to fabricate stainless steels shall not have been
previously used with other Steels.
Stainless steel shall be electrically isolated from all other metals.
3.9.2 Fasteners
3.9.2.1 Materials
All stainless steel fasteners (i.e. bolts, nuts, washers, studs, rods, etc.)
shall be to BS EN 10088 and BS EN ISO 3506. Stainless steel grade NA
shall be in accordance to Table 3-3
 Holding down bolts shall be super-duplex stainless grade steel type
UNS S32750 (1.4410) or UNS S32760 (1.4501) in accordance Unified
Numbering System with BS EN 10088. Hold down bolts shall have
mechanical strength properties in accordance with property class 80
(or better).
3.9.2.2 Installation.
The length of each bolt shall be such that the threaded portion will
project through the nut by at least one and one half complete threads.
All fixings cast in concrete shall be stainless steel unless noted
otherwise. Bolts shall be tightened using a standard wrench to a
"snug-tight" condition, unless noted otherwise on the drawings.
Stainless steel fasteners shall be electrically isolated from dissimilar metals
NA
by use of insulating gaskets, insulating washers and insulating bushes as
appropriate.
At the end of the practical completion period the CONTRACTOR Shall
ensure that all bolts are tight.
3.9.3 Welding
All electrodes, welding techniques and procedures shall comply with
the requirements, as applicable, of BS EN 1011-3, BS EN ISO 3581,
BS EN ISO 14343 and BS EN ISO 17633.
All welds shall be continuous, unless specified otherwise. A weld once
started shall be completed without any interruption.
Avoid distortion of welded sections and the cracking of welds where
the geometry of the joint as well as the metal thickness may affect the
NA
cooling rate and tend to produce distortion.
Accurately align and handle the sections prior to and during welding.
Any welds which are defective or unsound shall be removed, replaced
or otherwise corrected in accordance with the Specification and
relevant Standards.
3.9.4 Pickling and Passivation.
Stainless steel items and welded areas on stainless steel must be
passivated.
Cleaning and passivation shall be carried out before installation to
NA
ensure that the protective chromium oxide film is fully effective.
 Bolts, nuts and washers and other small items must be cleaned and
passivated by an overnight soak in 15% dilute nitric acid followed by
a thorough washing in fresh water.
Items too large to be treated using the method outlined above must
be treated using "SANDVIK" Pickling Paste or approved equivalent
used strictly in accordance with the manufacturer's printed directions.
Welded areas on fabricated stainless steel items shall be passivated
by treating with "SANDVIK" Pickling Paste or approved equivalent
used strictly in accordance with the manufacturer's printed directions.
3.9.5 Handling and Storage
Support must be provided so that the stainless steel maintains its
shape. Stainless steel shall not be in contact with other carbon steels.
Stainless steel shall be handled and stored in a manner that does not
allow damage to its surface. If damage to the surface occurs, it should
be passivated in accordance with this Specification. NA
The surface of stainless steelwork shall be kept clean and free from
grease, dirt and the like at all times cleaning can be carried out by
using mild detergents or soap and warm water, followed by thorough
rinsing with cold water.
3.10 Bolted Connections
3.10.1 General
The CONTRACTOR must provide the EMPLOYER'S
REPRESENTATIVE with a test certificate confirming for the material
properties of the bolts and connectors. The test certificate must be NA
able to be traced back to the washers must be provided for tapered
flange sections.
3.10.2 Bolts
Bolts for structure and the other purposes shall, unless otherwise
noted, be high strength metric both to ES 4190 grade 8.8 or higher.
Where required ISO metric precision bolts shall be to BS 3692. Metal
washers shall be to BS 4320. Taper washer shall to BS 3410.ISO NA
metric black cup and countersunk head bolts and screws with
hexagon nuts shall company with BS 4933.
All bolts, except stainless steel bolts, shall be hot dip galvanised.
 High strength friction grip bolts and associated nuts and washers shall
comply with relevant sections of BS EN 14399 and BS EN 1993-1-8.
Hardened steel washers shall be provided under both the head and
nut of each bolt. High strength friction grip bolts which have been
tightened and subsequently released shall not be used in permanent
works
The minimum size of bolt used on all standards connections shall be
12 mm diameter unless otherwise approved by the EMPLOYER'S
REPRESENTATIVE
Single bolt connections will not be permitted.
Bolts in tension will not be allowed, the only exception being
foundation bolts.
Where pin bolting is used for assembly and erection of joints which
are finally welded, pin bolts shall be omitted from the strength
calculations of the joint.
Where specific coatings are required to fasteners they shall be
provided by the fastener manufacturer and shall comply with the
appropriate part of BS 7371.
Bolts must be tightened using the turn of nut
method unless noted otherwise on the Drawings.
Bolts in shear must be of such lengths that no threaded portion is
within the thickness of the parts joined.
Bolts shall be threaded only over the length of shank which is
outside the parts bolted together with one full and the thread
run-out clear between the unthreaded shank and the
tightened nut.
The bolt shall protrude by at least two complete threads and not more
than four complete threads beyond the face of the tightened nut.
3.10.3 Bolt Holes.
Bolt holes for bolts up to M24 must be 2 mm larger in diameter than
the nominal bolt diameter and for bolts larger than M24, 3 mm larger
in diameter than the nominal bolt diameter unless noted otherwise
on the Drawings.
NA
Bolt holes for connecting steelwork to cast-in holding down bolts,
must be 6 mm larger than nominal bolt diameter for M24 and smaller
 bolts, and 8 mm larger than nominal bolt diameter for bolt diameter
greater than M24.
Where slotted holes are specified or shown, such holes must be
accurately shaped with sides smooth, parallel and semi-circular at
the ends. Length of slotted holes must be defined as the distance
between centres of drilled or punched holes.
Holes for bolts must be drilled, or punched (for plates up and
including 12 mm thickness) and must in no instance be flame cut.
The areas around holes must be smooth and free of burrs and fins
or other defects, which may prevent solid seating of the contract
surface.
Holes may be punched to at least 3 mm undersize and then reamed
to full size. Punching of holes in material with a thickness greater
than 12 mm is not permitted ,
After assembly of the parts to be joined , all holes must be true
throughout, perpendicular to the face of the member and aligned so
as to permit the bolts be positioned without damage to the threaded
portion.
Holes through tubular members must be lined with sleeves and an
external fillet weld run around the perimeter of the sleeve to seal the
gap between the sleeve and the wall of the tube
3.10.4 Requirements for Fixing Concrete
Where approved by the EMPLOYER 'S REPRESENTATIVE, holes
for bolts may be drilled in concrete after it is hardened. Care shall be
taken to ensure that damage to steel reinforcement does not occur.
The holes shall be drilled using a rotary percussive drill employing
air or water flushing of the hole. Holes shall be carefully cleaned and
blown out before the fixings are placed and grouted.
The use of diamond bit drilled holes will not be permitted, unless the
NA
CONTRACTOR can demonstrate to the EMPLOYER 'S
REPRESENTATIVE that reinforcement has been accurately located
and will not therefore be cut by the drilling. In the event that approval
for diamond bit drilling is given and reinforcement is subsequently
cut, the CONTRACTOR shall carry out any additional remedial
 works that the EMPLOYER'S REPRESENTATIVE may instruct at
the CONTRACTOR’s expense. Any diamond bit drilled holes to
accommodate anchor bolts shall be thoroughly roughened as
recommended by the bolt anchor grout manufacturer and to the
satisfaction of the EMPLOYER'S REPRESENTATIVE.
Preformed holes for foundation and holding down bolts shall be
formed by boxes of accepted type which can be struck cleanly or
which are suitable to be left in or by expanded metal sleeves.
Polystyrene blackout forms shall not be removed by burning. After the
concrete surrounding the boxes or sleeves has hardened and the
form stripped if necessary, the holes shall be cleaned out and
temporarily plugged until the bolts are to be fixed. Any damage to
holes shall be made good by the CONTRACTOR.
All rag bolts or indented bolts shall be of accepted type and shall be
accurately set in position with the shank extending so that two threads
will protrude past the nuts. They shall be set before the concrete is
placed and care shall be taken to protect the bolt threads. Before bolts
are grouted in, the holes shall be thoroughly cleaned. Grout of the
type indicated or otherwise accepted shall be placed in the hole and
around the bolt and the surface shall be finished to present a uniform
appearance with its surroundings.
Patent fixing arrangements shall be fitted in accordance with
manufacturer's recommendations.
All fixings into concrete shall be electrically isolated from the re
enforcing steel to avoid bimetallic Corrosion.
Where fixings are of dissimilar metal to the items being fixed, they
shall include suitable isolated washers to ensure that there is no
electrical contact between the fixing and item.
Specific requirements for chemically cured and resin grout are
covered in Section 3.10.5 of this specification. The use of expansion
type mechanically anchored bolts will not be permitted.
3.10.5 Chemical Anchors
Chemical anchors shall consist of bolts installed in grout consisting NA
of chemically cured epoxy resin suitable for a marine environment.
 Where anchorage holes are drilled horizontally the resin shall be
installed in capsules and the anchor bolt installation shall be carried
out strictly in accordance with the manufacturer’s written
instructions. The drilled holes shall be irregular and dust free and
shall be drilled using a rotary percussive drill on air or water flush.
Diamond bit drills shall not be used.
10 percent of the 100 of each type of chemical anchor installed shall
be tested with a pull-out test up to the manufacturer’s stared safe
working load of the fixing. Provided that the tests on all these
anchors are satisfactory the rate of the testing maybe reduced to N/A
5%. When requested by the EMPLOYER’S REPRESENTATIVE the
CONTRACTOR shall undertake in situ tension tests on selected
anchorages to demonstrate the adequacy of the anchorage, at the
CONTRACTOR 's own expense
The CONTRACTOR shall provide to the EMPLOYER 'S
REPRESENTATIVE for review and approval details of the
anchorage system proposed, which shall include the following:
Name of resin anchorage manufacturer
• Type of resin;
• Bolt diameter ;
• Bolt anchorage length;
• Hole diameter;
• Method of installation ;
• Date of Manufacturer.
When requested by the EMPLOYER'S REPRESENTATIVE, the CONTRACTOR
shall undertake in situ tension tests on selected anchorages to demonstrate
the adequacy of the anchorage, at the CONTRACTOR's own expense.

3.11 Welding
3.11.1 General
All weld ing materials, workmanship , inspection and testing must conform to
the following standards for the grades and thicknesses of steel and the types
of weld specified, unless otherwise stated in this Specification :
• BS EN ISO 2560 : Covered electrodes for manual metal arc
welding of mild steel and medium tensile steel;
 • BS EN ISO 17636: Radiographic testing;
• BS EN ISO 17640: Ultrasonic Testing ;
BS EN ISO 14171 and BS EN ISO 14174: Welding
Consumables;
• BS EN ISO 15607: Specification and qualification of welding
procedures for metallic materials General rules;
• BS EN 1011: Welding - Recommendations for welding of
metallic materials.
The CONTRACTOR must develop and submit to the EMPLOYER 'S
REPRESENTATIVE for approval details of all weld procedures required to
carry out the work including, a weld plan, welders ' certificates, welding
supervisor's certificates, welding inspector's certificates, and quality
assurance documentation setting out systems that will be used for all welding
work . The quality assurance documentation may form part of the Inspection
and Test Plan (ITP).
The CONTRACTOR must produce a set of weld procedures which must
FME Usually following AWS D1.1 for
be approved before welding commences. fabrication.
Welding sequences and procedures must ensure that distortion or restraint
to welds is minimized and completed fabricated steelwork remains within
specified fabrication tolerances.
The types, dimensions and lengths of all welds shall be clearly shown on
the Drawings.
Welds thickness shall not be less than the thickness of welded members
unless otherwise shown on the Drawings and they shall be designed in
according with relevant sections of BS EN 1993 to resist the loads and
forces to be transmitted by the various members.
The arrangement of welds shall be designed to taken into account the
distribution of all stresses and any eccentricities arising from the welds
relative to the axes of the members.
3.11.2 Weld Details and Quality
The finished surface profile of all welding must be smooth and free from
sharp edges, undercutting, defects, or any other discontinuities that would
be detrimental to the performance of the structure or to the protective
treatment. All slag and traces of weld splatter must be removed from the
weld zone and weld surfaces must be replaced, repaired and ground
smooth.

l
All unqualified tack welds must be completely removed prior to welding.
Where qualified tack welds are to be incorporated into a final weld made
by a different process to that used for the tack weld , consumables of
Equivalent strength must be used for both processes and the tack welders
must be qualified.
The arrangements of the runs in multi-run welds shall be such as to
 avoid the formation of slag traps and to ensure
Adequate root penetrations and correct shapes of the welds.
Unless otherwise directed, the sizes of the electrodes and the number of
runs necessary to make each welded joint shall conform to the electrode
manufacturer's recommendations.
All welds shall be continuous unless otherwise approved by the
EMPLOYER 'S REPRESENTATIVE. Welds showing blowholes or similar
defects will be rejected.
Penning of the welds involving deformation of the weld surface shall not
be allowed whether during de-slagging or subsequently.
Plant, equipment, accessories and connections shall be maintained in Complied
proper working order.
Plant used in welding shall be of sufficient capacity to comply with the
required welding procedure and shall be capable of depositing the various
types of electrodes used under the conditions of current and voltage
specified by the manufacturer of the electrodes.
Efficient means shall be provided for the accurate indication of the current
and, in addition , a pair of test tongs shall
be supplied by the CONTRACTOR and be available for use by the
EMPLOYER'S REPRESENTATIVE .
3.11.3 Welding personnel
3.11.3.1 Welders
All welders must be qualified to the following standards.

• BS EN ISO 9606: Qualification testing of welders- Fusion welding Part 1: Steels ·

• BS 4872-1 : Acceptance testing of welders when welding
procedure acceptance is not required . Part 1 – Fusion welding
of steel
The EMPLOYER'S REPRESENTATIVE may request to inspect the
welding certificate for any welder and/or to witness the welding of a test
piece by the welder. Copies of all welders' certificates must be kept on Site.
Welders who have failed a repeat acceptance test must not be permitted FME have AWS D1.1 welders.
to weld. welders who fail any periodic test shall be given another test as
soon as practicable and shall be deployed on welding only after passing
such a retest.

3.11.3.2 Welding Supervisors

All welding must be supervised by personnel who have had suitable
training and are adequately experienced in the fabrication of welded
structures. These welding supervisors must be certified by a reputed
organization and shall be subject to approval by the EMPLOYER'S Complied
REPRESENTATIVE.
3.11.3.3 Welding Inspector
The CONTRACTOR must appoint a welding inspector to test welds in
accordance with the requirements of the ITP, and to ensure that all welds
and the welding workshop, equipment, and personnel meet all British
Standards. Welding inspector must be must be certified by a reputed FME have CSWIP 3.1 certified inspector.
organization and shall be subject to approval by the EMPLOYER'S
REPRESENTATIVE.
3.11.3.4 EMPLOYER’S REPRESENTATIVE’s welding Inspector.
The EMPLOYER'S REPRESENTATIVE may at its own cost choose to
appoint a third party welding inspector to witness any part of the welding
or surface preparation process.
The CONTRACTOR must provide the EMPLOYER'S
REPRESENTATIVE's welding inspector with full access to allow them to
witness all welding, and provide them with any further assistance that they
‘required. The CONTRACTOR must supply all labor, power and tools
required by the welding inspector to enable them to complete their Complied
inspection at no cost to the EMPLOYER'S REPRESENTATIVE.
The EMPLOYER'S REPRESENTATIVE has the right to reject any non-
complying welds.
3.11.4 Steel Preparation
Edge preparation for butt welds shall be mechanically cut or plasma cut.
Plates and components that are to be welded must be assembled, aligned
and retained in position for welding to ensure that the dimensions and
tolerances specified for the particular joint preparation are maintained
during the welding process.
Preheating of members before welding shall be carried out in accordance
with BS EN 1011.
A digital temperature gauge or temperature crayons must be used to
measure the temperature of the steel during the preheating.
If members or plates are bent or set, the bends and sets must be made to
the radii and angles specified and must be free from hammer marks. Edges
of plates to be bent must be ground smooth prior to bending.
All plates, gussets, steel members, etc. must have sharp edges and
corners rounded and ground smooth to a radius of 2mm. This is to ensure Complied
that the effectiveness of the corrosion protection coating is not reduced at
edges and is not required where such edges are subsequently to be
welded.
The welding zone of all steelwork must be free of paint, rust, grease or any
other deleterious matter prior to welding taking place.
3.11.5 Workshop Welding.
Plates to be joined by welds must be brought into contact as practicable,
but no case shall the separation exceed 3mm if the plate is 6 mm or thicker,
 or 1.5 mm if the plate is less than 6mm thick.
Fillet weld leg size may need to increase by up to 1.5 mm to suit fit up
requirements of abutting plactes.in no case shall the gap/misalignment in
the plates exceed 1.5 mm.
Plates or sections to be welded must be held in the correct position by tack
welds, bolts, clamps, shims and wedges, guys, struts, or other suitable
devices until the welding is complete . Jigs and fixtures must be used
where practicable.
Welding in exposed locations must not occur during inclement weather
such as wind or rain. Use of cut-outs and snipes in plates, e.g., mouse
holes, etc, for fitments to aid welding access and assembly of stiffeners
and fitments is not permitted unless otherwise approved by the
EMPLOYER'S REPRESENTATIVE .
All fabricated or rolled hollow sections must be air-tight after fabrication
and installation.
Electrodes for welding shall be covered
electrodes suitable for metal-arc welding
complying with BS EN ISO 2560. A
manufacturer's certificate to this effect shall
be obtained for each consignment of
electrodes. The electrodes shall be suitable Complied.
for each individual weld and the classification
of the electrodes shall be in accordance with
BS EN ISO 2560. Full particulars of such
classification shall be submitted to the
EMPLOYER'S REPRESENTATIVE for his
approval before any welding is commenced.
For welding in any particular position the
electrodes used shall be those
recommended by the manufacturer for use in
that position.
Electrodes shall be stored and kept under dry conditions
and any electrode which has become damaged by
moisture shall not be used unless it is stated by the
manufacturer that when the electrode is properly dried
there Remains no detriment. Any electrode which has
part of its flux coating broken away or is otherwise be
discarded.
3.11.6 Structural Hollow Sections
Structural steel tubes, rectangular or square
hollow sections and fabricated plate hollow
sections which are to be welded must not be
sheared, but must be accurately cut and
profiled to fit the shape of the members to
 which they are to be welded .
All butt welds of hollow members must be
backed by suitable mild steel backing rings
or plates, unless otherwise approved by the
EMPLOYER'S REPRESENTATIVE.
All hollow sections must be fully sealed with
a 10 mm thick welded steel sealing plates as
required to ensure that they remain air-tight
after installation unless otherwise approved
Complied.
by EMPLOYER'S REPRESENTIVE.
The steel material properties of the sealing
plate must match the material being sealed
unless otherwise approved by the
EMPLOYER’S REPRESENTATIVE.
3.11.7 Inspection and Testing
The CONTRACTOR shall provide all
facilities to the EMPLOYER'S
REPRESENTATIVE, for inspection of
welding at any reasonable time at all places
where welding is being done. The decision of
the EMPLOYER'S REPRESENTATIVE
regarding the approval or rejection of any
work will be final.
Testing of welds shall be carried out to the
extent set out in the Schedule or as
instructed by the EMPLOYER'S
REPRESENTATIVE. Such testing shall
comply with the requirements of the
appropriate British Standards where
applicable. The test specimens shall be
supplied, packed and forwarded free of
charge and any test not satisfying the
Specification shall be paid for by the
CONTRACTOR. For schedule of weld test
see Clues 3.6.1.2.
Any area of the weld which is found to be Complied
unacceptable shall be found out and re-
welded. Such grinding shall be done with a
tapering transition from the unacceptable to
the acceptable part of the weld.