Structural Steel: Salient Features of IS:2062-2011: EOC Noida

STRUCTURAL STEEL: SALIENT FEATURES OF
IS:2062-2011
EOC Noida
CONTENT Click to edit Master title style
EOC Noida
 STRUCTURAL WORK IN A THERMAL POWER STATION

 SCOPE OF IS: 2062
 MANUFACTURING & SUPPLY CONDITIONS AS PER IS 2062
 ROLLING PROCESS IN STEEL MAKING
 KILLED/SEMI-KILLED STEEL
 VACUUM DEGASSING
 GRADES/SUB-QUALITIES OF STEEL AS PER IS:2062
 MICRO-ALLOYING ELEMENTS
 TESTING REQUIREMENTS AS PER IS:2062
 NTPC SPECIFICATION’S REQUIREMENT AS PER IS: 2062
 TEST CERTIFICATE OF STEEL AS PER IS:2062
Copyright © 2016 Your Company All Rights Reserved. 2

Click to edit Master title
MAIN PLANT BUILDINGS/STRUCTURES style
 Main Power House
 Mill Bunker Building
 Machine Foundations in Main Plant
 Boiler Supporting Structure
 Compressor House
 ESP Supporting Structure including inlet and exhaust duct support structures.
 ESP Control Building
 Miscellaneous Equipment Foundations & Pipe Cable Trenches/ and Pedestals
below finished ground level
 Pipe Cable Galleries & Trestles
 Service Building
 Transfer Points, Conveyor Galleries & Trestles.

ClickWORK
MAJOR STRUCTURAL to edit
IN AMaster
THERMALtitle styleSTATION
POWER
TG Boiler Supporting ESP Supporting CHP

Structure Structure Structure Supporting
Structure
Sl No. Area Quantity of Structural
Steel (approx. MT)/unit
01 TG Structure 18000
02 Boiler Supporting Structure 14,000
03 ESP Supporting Structure 7500
04 CHP Supporting Structure 8000

Click to edit Master
SCOPE OF IS: 2062 title style
 IS:2062 covers hot rolled medium and high tensile structural steel,
including micro alloyed steel plates, strips, shapes, sections, flats,
bars etc.
 These steels are suitable for welded, bolted and riveted structures.

Manufacturing &Click
supplytoconditions
edit Master titleISstyle
as per 2062
 The processes used in steel making, casting & further hot rolling are left on discretion of
manufacturer’s.
 Steel may be supplied in semi-killed/killed condition based on mutual agreement between

purchaser & supplier.
 Steel may be ingot cast or continuously cast.
 For any special quality of steel, which requires secondary refining processes such as vacuum de-
gassing shall be mutually agreed between purchaser & supplier.
 Material produced by re-rolling of finished products(virgin or used or scrap), or by rolling of

material for which metallurgical history is not fully documented or not known, are not acceptable
as per this code.
Click
Rolling process in tomaking
steel edit Master title style
Rolling is a metal forming process in which metal stock is

passed through one or more pairs of rolls to reduce the
thickness and to make the thickness uniform.

Click to
Basis of Classification of edit Master
Rolling title style
Processes
Rolling processes are classified according to the

temperature of the metal rolled.

HOT ROLLING PROCESS title style
If the temperature of the metal is above its
recrystallization temperature, then the process is
known as hot rolling. After the grains deform during
processing, they recrystallize, which maintains
an equiaxed microstructure and prevents the metal
from work hardening. Hot rolling is used mainly to
produce sheet metals & plates etc.

RECRYSTALLIZATION title style
 Recrystallization is the process in which deformed grains of the crystal structure

are replaced by a new set of stress-free grains that nucleate and grow until all the
original grains have been consumed.
 The process is accomplished by heating the material to temperatures above that

of recrystallization temperature.
 In other words recrystallization causes changes in grain size, orientation and

relieves stress.
 The recrystallization temperature for steel is around 700 °C.

CONTROLLED ROLLING title style
 It is a hot rolling process in which the temperature of the steel and its reduction
ratio are controlled, particularly during the final rolling passes, in order to achieve
fine grain microstructure and optimum mechanical properties (strength and
toughness).
 The processing conditions are controlled to refine the austenite structure and
thereby give fine ferrite grains. Refinement of the structure is aided by the
addition of micro-alloying elements such as Nb, V or Ti.
 The improved strength and toughness of controlled rolled steels are shown to be
a result of the fine grain size.

NORMALIZED ROLLING title style
It is a type of hot rolling process in which the final rolling passes are carried out at
normalizing temperature, followed by cooling in air to a temperature below the
transformation temperature. Normalization eliminates internal stresses, strains and
improves the mechanical properties of the steel, such as improving its toughness
and machinability. A better ductility can also be obtained without compromising the
hardness and strength.
The usual normalizing temperature of steel is around 810-923 deg C

Click to edit
FURNACE NORMALIZING Master
PROCESS title style
In this process material is heated up to normalizing temperature and

left in furnace for cooling.

Click
Killed/ Semi-killed steelto edit Master title style
 Killed steel is steel that has been completely deoxidized by the addition of
agents(like Al, Si) before casting, so that there is practically no evolution of gas
during solidification. The steel is said to be "killed" because it will quietly solidify in
the mould, with no gas bubbling out.
 Semi-killed steel is not fully deoxidized steel and contains carbon monoxide
which leaves blowhole type porosity distributed throughout the ingot. For semi-
killed steel, silicon shall be less than 0.10%.

Click
Characteristics of tosteel?
killed edit Master title style
Killed steels have high strength for the same grade of steels.
They have high degree of chemical homogeneity and are free
from gas porosity.

Click
Vacuum de-gassing of to edit Master
steel? title style
 During steel making, gases like oxygen, hydrogen and nitrogen dissolve in steel.
Vacuum degassing process refers to the exposure of molten steel to a low-
pressure environment to remove nitrogen and hydrogen from steel. As at low
pressure solubility of these gases in molten metal decreases, these gases get
removed at lower pressure (vacuum).
 Dissolved oxygen from steel melt cannot be removed even at low-pressure.

Removal of oxygen is termed de-oxidation/killing.

Click to of
Why vacuum de-gassing edit Master
steel title style
is required?
Vacuum de-gassing of steel is employed to achieve strict quality parameters. It is

practiced in the steel industry for several purposes. Such as:
-to remove hydrogen & nitrogen
-to produce steel of low carbon content ( < 0.03%)
-to produce steels of close chemical composition ranges (including deoxidizers).

Click to& edit
Why removal of hydrogen Master
nitrogen titleisstyle
from steel necessary?
 Both nitrogen and hydrogen impair the mechanical properties of steel. The maximum solubility of
nitrogen in liquid iron is 450ppm and less than 10ppm at room temperature. During solidification if
excess nitrogen is rejected, it may form blow holes. Excess nitrogen causes embrittlement of heat
affected zone of welded steels and impair cold formability.
 Solubility of hydrogen in steel is low at ambient temperature. Excess hydrogen if rejected during
solidification, results in pinhole formation and porosity in steel. Presence of hydrogen causes
blistering and loss of tensile ductility.
 Thus removal of nitrogen and hydrogen from steel is necessary.
% of nitrogen in steel should not be more than 0.012%.

Click to edit
What are the micro-alloying Master title
elements? style
 Elements such as Nb, V, Ti added singly or in combination to obtain higher

strength to weight ratio combined with better toughness, formability and
weldability as compared to unalloyed steels are called micro-alloying elements.
 Total micro-alloying elements shall not be more than 0.25%.

Click
How many grades to edit
of steels areMaster
there intitle style
IS:2062?
 There are nine grades of steel in IS 2062 (E250, E275, E300, E350,
E410, E450, E550, E600 & E650).
 This grade designation system is based on “MINIMUM YIELD

STRENGTH”.

Click toare
How many sub-qualities edit Master
there title style
in IS:2062?
For grades E250 to E 410 there are four Sub-qualities (A, BR, B0 & C)
and for grades E450 to E 650 there are two Sub-qualities (A & BR).

Click toindicate?
What does sub-qualities edit Master title style
Sub-qualities indicates “requirement of impact test and mode of de-oxidation”.
 A: Impact test not required, semi-killed/Killed
 BR: Impact test optional; if required at room temp.; semi-killed/Killed
 B0: Impact test mandatory at 0 deg C, semi-killed/Killed.
 C: Impact test mandatory at -20 deg C, Killed.

Click toisedit
How carbon equivalent Master
calculated? title style
Carbon equivalent(CE) is calculated based on the Ladle analysis and given by the
formula,
CE= C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15
Range of C (%) in IS: 2062 is from 0.20 to 0.23.
Increased carbon content increases the yield and tensile strength, but decreases
the ductility and weldability,

24
Click to editCOMPOSITION
CHEMICAL Master title style
GRADE LADLE ANALYSIS, PERCENT, Max. CARBON EQUIVALENT
QUALITY MODE OF DEOXIDATION
DESIGNATION C Mn S P Si (CE), Max.
A 0.23 1.50 0.045 0.045 0.40 0.42 Semi-killed/killed
BR
E 250 0.22 1.50 0.045 0.045 0.40 0.41 Semi-killed/killed
B0
C 0.20 1.50 0.040 0.040 0.40 0.39 Killed
A 0.23 1.50 0.045 0.045 0.40 0.43 Semi-killed/killed
BR
B0
C 0.20 1.50 0.040 0.040 0.40 0.41 Killed
A
BR 0.20 1.50 0.045 0.045 0.40 0.44 Semi-killed/killed
E 300
B0
C 0.20 1.50 0.040 0.040 0.45 0.44 Killed
A Semi-killed/killed
BR 0.20 1.55 0.045 0.045 0.45 0.47
E 350
B0
C 0.20 1.55 0.040 0.040 0.45 0.45 Killed
A
BR 0.20 1.60 0.045 0.045 0.45 0.5 Semi-killed/killed
E 410
B0
C 0.20 1.60 0.040 0.040 0.45 0.5 Killed
A
BR
E 550 0.22 1.65 0.020 0.025 0.50 0.54
BR
E 600 0.22 1.70 0.020 0.025 0.50 0.54
BR
E 650 0.22 1.70 0.020 0.025 0.50 0.55
BR

25
ClickMECHANICAL
to edit Master title style
PROPERTIES
Yield Stress Internal Bend Diameter Min CHARPY IMPACT TEST
TENSILE STRENGTH
GRADE ReH, Min. Mpa Percentage Elongation A, Min (See note 2) (See Note 3)
QUALITY
DESIGNATION Rm, Min. Mpa (1) at Gauge Length, Lo=5.65 Temp Min
< 20 20-40 > 40 ≤ 25 ≥ 25
(See Note 1) deg C J
A - -
BR RT 27
E 250 410 250 240 230 23 2t 3t
B0 0 27
C (-) 20 27
A - -
BR RT 27
E 275 430 275 265 255 22 2t 3t
B0 0 27
C (-) 20 27
A - -
BR RT 27
E 300 440 300 290 280 22 2t -
B0 0 27
C (-) 20 27
A - -
BR RT 27
E 350 490 350 330 320 22 2t -
B0 0 27
C (-) 20 27
A - -
BR RT 25
E 410 540 410 390 380 20 2t -
B0 0 25
C (-) 20 25
A - -
E 450 570 450 430 420 20 2.5t -
BR RT 20
A - -
E 550 650 550 530 520 12 3t -
BR RT 15
A - -
E 600 730 600 580 570 12 3.5t -
BR RT 15
A - -
E 650 780 650 630 620 12 4t -
BR RT 15
NOTES
1 In case of product thickness/diameter more than 100 mm, lower minimum limit of tensile strength may be mutually agreed to between the purchaser and the manufacturer/ supplier
2 Bend Test not required for thickness> 25 mm for grades E 300 to E 650. 't' is the thickness of the test piece
3 For sub-quality BR, impact test is optional; if required, at room temperature (25 ± 2°C)
1) 1 MPa= 1N/mm 2=1 MN/m 2=0.102 kgf/mm 2=144.4 psi
NTPC SPECIFICATION FOR DIFFERENT PROJECTS
Project Name
26
Steel Type
Click to edit Master title style
Thickness of Plates Material Specn./Grade Impact Test
Requirement
(Killed/Semi Killed etc) Type of Rolling Degassing
Bulk Tender Mild Steel Upto 20mm E250A - Semi.Killed - -

>20, upto 40 E250B - Killed Controlled Rolled -
>40mm E250B - Killed Normalised Rolled -
Medium & High Tensile Upto 20mm E350 - Semi.Killed - -
>20, upto 40 E350 - Killed Controlled Rolled -
>40mm E350 - Killed Normalised Rolled -
Tanda Mild Steel Upto 20mm E250A - Semi.Killed - -
>20, upto 40 E250B - Killed Controlled Rolled -
>40mm E250B - Killed Normalised Rolled -
Medium & High Tensile Upto 20mm E350 - Semi.Killed - -

>20, upto 40 E350 - Killed Controlled Rolled -
>40mm E350 - Killed Normalised Rolled -

N.Karanpura Mild Steel >12 upto 40 E250BR Impact Test at Room Temp. Fully Killed Normalised Rolled -
>40mm E250BR Impact Test at Room Temp. Fully Killed Furnace Normalised Vacuum Degassed
Medium & High Tensile >12 upto 40 E350B0 - Fully Killed Controlled Rolled -
>40 E350B0 - Fully Killed Furnace Normalised Vacuum Degassed

Khargone Mild Steel >12 upto 40 E250BR Impact Test at Room Temp. Fully Killed Normalised Rolled -
Medium & High Tensile >12 upto 40 E350B0 or higher - Fully Killed Controlled Rolling -
>40 E350B0 or higher - Fully Killed Furnace Normalised
Telangana Mild Steel >12 upto 40 E250BR Impact Test at Room Temp. Fully Killed Normalised Rolled -
Medium & High Tensile >12 upto 40 E350B0 - Killed Controlled Rolled -
>40mm E350B0 - Killed Normalised Rolled -
TESTING REQUIREMENTS title style

Test samples required asto
Click peredit
IS:2062 for Tensile,
Master title Bend
styleand Impact
testing ?
 Number of tests required:
 Tensile test: 2/cast/heat
 Bend test: 2/cast/heat
 Impact Test: 3/cast/heat (subject to at least one/cast/heat from thickest portion of

the product.)

Clicktests
NDT & Metallurgical to edit Master
requirement title style
 The material may be subjected to NDT(UT) to determine the soundness of material subject to
mutual agreement between the purchaser and the Mfr/supplier. Acceptance standard for UT is
ASTM 435 and ASTM 578.
 Metallurgical tests for grain size, directionality, inclusion content may be carried out subject to
mutual agreement between the purchaser and the Mfr/supplier.
Acceptance Standard for UT as per ASTM 435

“ - Any discontinuity indication causing a total loss of back reflection which cannot be contained within a circle,
the diameter of which is 3 in. (75 mm) or one half of the plate thickness, whichever is greater, is
unacceptable.
-The Manufacturer reserves the right to discuss rejectable ultrasonically tested plates with the purchaser with
the object of possible repair of the ultrasonically indicated defect before rejection of the plate.
-The purchaser’s representative may witness the test.”
contd…
Acceptance Standard for UT as per ASTM 578
Acceptance Standard-Level A :
 Any area where one or more discontinuities produce a continuous total loss of back reflection accompanied
by continuous indications on the same plane ( within 5% of plate thickness ) that cannot be encompassed
within a circle whose diameter is 75 mm or one half of the plate thickness , whichever is greater , is
unacceptable.
Acceptance Standards-Level B:
 In addition to Acceptance Standards-Level A , two or more discontinuities smaller than described above shall
be unacceptable unless separated by a minimum distance equal to the greatest diameter of the larger
discontinuity or unless they may be collectively encompassed by the circle described above.
Acceptance Standards-Level C :
 Any area where one or more discontinuities produce a continuous total loss of back reflection accompanied
by continuous indications on the same plane ( within 5% of plate thickness ) that cannot be encompassed
within a 25 mm diameter circle , is unacceptable.

Re-tests Click to edit Master title style
 If a test does not give the specified results, two additional tests shall be
carried out at random on the same lot. Both re-tests shall conform to
the requirements of this standard; otherwise ,the lot shall be rejected.
 Re-Heat Treatment: If any Heat treated material fails to meet the

mechanical requirements specified, the supplier may re-heat treat the
material and in that case, all mechanical properties shall be re-
evaluated.

MARKING & DELIVERY title style
 Every Heavy, Medium Structural mill and Plate mill product shall be marked with
the Cast Number. Plates produced from strip in coil form shall be marked with
cast/heat number on top plate of each pile/packet.
 The ends of the rolled products shall be painted with a colour code, as agreed to
between the purchaser and the manufacturer/supplier.
 Subject to prior agreement between the purchaser and the manufacturer/supplier,

suitable protective treatment may be given to the material after rolling.

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STRUCTURAL STEEL: SALIENT FEATURES OF

 STRUCTURAL WORK IN A THERMAL POWER STATION

Copyright © 2016 Your Company All Rights Reserved. 2

Copyright © 2016 Your Company All Rights Reserved. 3

TG Boiler Supporting ESP Supporting CHP

Copyright © 2016 Your Company All Rights Reserved. 4

Copyright © 2016 Your Company All Rights Reserved. 5

 Steel may be supplied in semi-killed/killed condition based on mutual agreement between

 Steel may be ingot cast or continuously cast.

 Material produced by re-rolling of finished products(virgin or used or scrap), or by rolling of

Rolling is a metal forming process in which metal stock is

Copyright © 2016 Your Company All Rights Reserved. 7

Rolling processes are classified according to the

Copyright © 2016 Your Company All Rights Reserved. 8

Copyright © 2016 Your Company All Rights Reserved. 9

 Recrystallization is the process in which deformed grains of the crystal structure

 The process is accomplished by heating the material to temperatures above that

 In other words recrystallization causes changes in grain size, orientation and

 The recrystallization temperature for steel is around 700 °C.

Copyright © 2016 Your Company All Rights Reserved. 10

Copyright © 2016 Your Company All Rights Reserved. 11

The usual normalizing temperature of steel is around 810-923 deg C

Copyright © 2016 Your Company All Rights Reserved. 12

In this process material is heated up to normalizing temperature and

Copyright © 2016 Your Company All Rights Reserved. 13

Copyright © 2016 Your Company All Rights Reserved. 14

Copyright © 2016 Your Company All Rights Reserved. 15

 Dissolved oxygen from steel melt cannot be removed even at low-pressure.

Copyright © 2016 Your Company All Rights Reserved. 16

Vacuum de-gassing of steel is employed to achieve strict quality parameters. It is

-to remove hydrogen & nitrogen

-to produce steel of low carbon content ( < 0.03%)

-to produce steels of close chemical composition ranges (including deoxidizers).

Copyright © 2016 Your Company All Rights Reserved. 17

 Thus removal of nitrogen and hydrogen from steel is necessary.

% of nitrogen in steel should not be more than 0.012%.

Copyright © 2016 Your Company All Rights Reserved. 18

 Elements such as Nb, V, Ti added singly or in combination to obtain higher

 Total micro-alloying elements shall not be more than 0.25%.

Copyright © 2016 Your Company All Rights Reserved. 19

 This grade designation system is based on “MINIMUM YIELD

Copyright © 2016 Your Company All Rights Reserved. 20

Copyright © 2016 Your Company All Rights Reserved. 21

Sub-qualities indicates “requirement of impact test and mode of de-oxidation”.

 A: Impact test not required, semi-killed/Killed

 BR: Impact test optional; if required at room temp.; semi-killed/Killed

 B0: Impact test mandatory at 0 deg C, semi-killed/Killed.

 C: Impact test mandatory at -20 deg C, Killed.

Copyright © 2016 Your Company All Rights Reserved. 22

Range of C (%) in IS: 2062 is from 0.20 to 0.23.

Copyright © 2016 Your Company All Rights Reserved. 23

Copyright © 2016 Your Company All Rights Reserved. 24

Bulk Tender Mild Steel Upto 20mm E250A - Semi.Killed - -

Medium & High Tensile Upto 20mm E350 - Semi.Killed - -

>40mm E350 - Killed Normalised Rolled -

>40 E350B0 - Fully Killed Furnace Normalised Vacuum Degassed

Copyright © 2016 Your Company All Rights Reserved. 27

 Number of tests required:

 Tensile test: 2/cast/heat