STEELWORK FABRICATION PROJECT PLAN

1. SCOPE

This procedure covers the general guidelines for the fabrication of Structural Steel
Works at factory/workshop/worksite.

2. CODES AND STANDARD

Governing Codes and Standards will be those, which are, stipulated in the project
specifications pertaining to the fabrication and welding of Structural Steel Works.

ASTM A123 Standard Specification for Zinc (Hot Dip

Galvanized Coating on Iron and Steel Products)

ASTM D3276 Standard Guide For Painting Inspectors

BS Structural Steel Sections

BS EN ISO 1641 Hot Dip Galvanized coating on fabricated iron and

steel
- Specification and test methods

BS EN ISO 14713 Protection against corrosion of iron and steel in

structure
Zinc and Aluminum coating guidelines

BS 4360 Structural Steel Sections

SIS 05 5900 Surface Of Steel Conditions and Preparation

BS 5493 Protective Coating of Steel Structures

BS 5950 Fabrication Specification

AWS D1.1: 2000 Structural Welding Code

JIS Japanese Industrial Standard

2.1 Responsibility

a) Process Department:-

Preparation of material requisition documents in accordance with contract

specifications throughout the project.
 b) Purchasing Department:-

Purchasing Department is to procure the material in accordance with

Client's requirement and specifications.

c) Store Department:-

Control ling material receiving, storage and release for fabrication.

2.2 Material Receiving

All incoming purchased and customer's property steel materials are received
at good inwards section at the stockyard. Purchasing Department shall inform
the related departments of the delivery schedule.

2.3 Inspection

Upon receiving purchased raw steels are checked by store personnel for the
followings as per the Delivery order:-

a) Quantity - Against Delivery Order, Purchase Order

b) Material Grade - Against Delivery Order, Purchase Order and Mill

Certificate

c) Dimensional - Against Delivery Order, Purchase Order

Once unloaded, the steels are segregated from other project materials. Color
codes may be applied for this purpose when necessary.

The Store personnel then request the QA/QC personnel for dimensions
and material and conformation to mill certification check. If any material is
found to be damaged excessively or if material received from mill does not
satisfy Governing Codes and Standard, they will be returned to supplier and
be the subject of compensation or replacement. For camber, profile flatness or
sweep the fabricator is permitted to perform corrective work by the use of
controlled heating and mechanical straightening.

Upon completion of QA/QC Inspection, the raw steel can then be released for
fabrication.

2.4 Inspection Record

Upon completion of QA/QC Inspection, the QA/QC personnel will prepare

the Inspection Report.

2.5 Material Requisition

Process Department shall prepare the material requisition. The material

requisition shall be transmitted to Store Department. Upon receiving of
Material Requisition, Store Department shall release the accepted material to
Process Department for fabrication.
2.6 Storage of Material

a) Material shall be properly handled and preserved to protect against

damage, corrosion and other harmful elements.

b) The personnel shall paste all accepted materials with M- ok sticker.

c) Material shall be completely segregated from other project with clear

identification in accordance with project specification and requirement.

d) Material shall be classified in to their types i.e. plate, section, tubular or pipe
etc and stored in each designated areas.

e) Welding consumable and paint shall be stored in the covered warehouse

within a waterproofed, secure and ventilated space.

2.7 Identification Color Coding System

For identifying the project and grade of steel, color-coding system shall be
used in accordance with the latest project color-coding table distributed. The
system shall be maintained throughout the project.

2.8 Purchase Order Specification For Steel Plates and Shapes

a) All steel shall be new, free of cracks, surface flaw and lamination,
camber and other defects.

b) Steel plate and shapes supplied to this specification shall comply with
requirement of BS 4360 or other Standards specified by Clients with
the amendment and variations as given in this specification.

c) A ladle analysis of steel shall be performed in accordance with the

requirement of the applicable specification. Test result shall be
reported on the mill certificates.

d) Special (optional) requirements for Testing shall be specified on the

Purchase Order.

e) The supplier shall provide certified Mill Test Report that contain the
name and location of mill, analysis of chemical and mechanical
properties and test results of special requirement.

f) The supplier shall provide certified Mill Test Report that contain the
name and location of mill, analysis of chemical and mechanical
properties and test results of special requirement.

g) Each steel shall be marked in accordance with the applicable

specification with the following additions.

a) Plate shall be die-stamped with heated number, plate number and

paint stenciled with manufacturer's name, brand or trademark,
size/thickness and material grade.
 b) Sections shall be marked with the heat number, size of sections,
length and mill identification mark on each piece, small shapes
with greatest cross sectional not greater than 150mm can be
bundled for delivery with each lift marked or tagged.

3. FABRICATION

3.1 Process of Fabrication

a) Shop fabrication of steel structural shall be performed in accordance

with approved shop drawings.

3.2 Cutting

a) Allowance to compensate shrinkage due to welding and/or gas cutting

will be regarded at the time of cutting plan preparation.

b) Cutting if materials will be done as follows:-

a) Plate: Plate will be cut using Automatic Gas

Cutter, Shearing Machine or Gas Cutter.

b) H-Shapes: H-shapes will be using Automatic Gas

Cutter, Semi-Automatic Gas Cutter and Gas
Cutter.

c) Channel & Angles: It will be cut using Band Saw, Semi-

Automatic Gas Cutter, Shearing Machine
and Gas Cutter.

d) Tubes & Pipe: It shall be using Band Saw, Semi-Automatic

Circular Gas Cutter and Gas Cutter.

c) Beveling will be done with automatic gas cutter, semi-automatic gas

cutter and/or Beveling Machine.

d) Cutting surface shall be at designated angle. A smooth, uniform cut

and free from slag, fins tears, cracks, burns and any other
discontinuities, which adversely affect the quality or strength of the
weld.

3.3 Drilling

a) Holes shall be drilled by machine with its drilled perpendicular to the

steel at the surface.

b) All holes shall be accurately located and shall be drilled to the size as
shown on the shop drawing.

c) For correctness of the holes location, templates representing gussets

and braces with bolt’s holes may be made on the base of full size
drawing of the gussets to braces connection scribed on the floor of the
mould loft or by the CAD system in accordance with Shop Drawing.
 d) Fabrication parts shall have marking number made by punching or
handwriting on the steel.

3.4 Hot-Dip Galvanized

a) Once the beams, channels, angles, plates are cut, drilled or sawn, metal
tag with embossed marking shall be tied-up using steel wire to identify
the articles of galvanizing. Metal tag shall not be tack welded to the
articles. If metal tagging is not feasible, the articles shall be clearly
stenciled at each end.

b) Before being delivered to the galvanizing plant, the articles shall be

cleaned of paint, oil, grease, heavy oil, welding spatters and welding
slag. This can be done by either sweep blasting, grinding, buffing and
chipping the articles.

c) The Material Coordinator shall check to ensure that the correct

quantity, quality, identification and size if the articles received at the
galvanizing plant are suitable and acceptable for galvanizing. Any
defective articles found for remedial action shall be segregated and
reported to the Material Coordinator.
 d) Where is necessary to drill holes for filling, venting or draining, this
shall be done according to the Design for Galvanizing Standard on
their sizes, locations and number of holes. Special precaution shall be
taken to ensure that hollow sections,i.e. handrails, pipes and welded
structural members have sufficient venting holes to prevent explosion
and uncoated spot occurrences.

e) Handling of articles shall be done in a systematic manner with proper

material handling equipment to ensure that there will be no damage on
the articles.

f) Articles to be galvanized shall be properly segregated from either

galvanized articles. Galvanized and non-galvanized articles shall be
supported by at least one foot high of wooden blocks and stored in a
clean and dry environment.

4. WELDING

4.1 Welding Process

The following welding processes shall be used as necessary

a) SMAW (Shield Metal Arc Welding)

b) SAW (Submerged Arc Welding)

c) FCAW (Flux Cored Arc Welding)

d) GMAW (Gas Metal Arc Welding)

e) GTAW (Gas Tungsten Arc Welding)

t
4.2 Welding Procedure Specification (WPS)

Welding procedure specifications or Weld Map shall be prepared for the entire
scope of work to be undertaken. The QA Department will prepare the Welding
Procedure Specification. The procedures shall include all of the information
necessary for guidance and instruction to welding personnel to ensure
adherence to the Governing Codes and Standards.

4.3 Welding Consumable

These electrodes shall be bakes in accordance with their respective

classification conforming designation and type. Drying temperature and
holding time shall be maintained in accordance with applicable code or
instruction recommended by the manufacturer (refer to the Welding Procedure
Specification). Welding consumable that has been removed from the original
package shall be protected and stored so that the welding properties are not
affected.
Control and handling of consumable welding shall adhere “Welding
 consumables control and issue procedure ”

4.4 Atmospheric Condition

Welding shall be carried out in the area protected from rain and wind.
Welding shall not be carried out when the surface of weld is wet.

4.5 Welding Technique

Preparation of Material

a) Welding edges will be prepared by grinding, machine or other means

after cutting.

b) Surface and edge to be welded shall be smooth uniform clean and free
from cracks notches or other irregularities.

Tack Welding

a) Tack welding shall be in accordance with AWS D1.1:2000 Section

5.18.

b) It shall be subject to the same quality requirement as the final weld.

c) Prior to performance of the welding tack maybe be made by manual

arc welding to assure alignment and fit-up.

Welding Process

a) Ensure satisfactory root pass or fit bead, alignment and electrode

manipulation shall be carefully controlled.

b) When starting with new electrode, the use of a striking bar is

recommended.

c) There shall not be excessively high or low spot in the weld run.

d) The surface of final bead shall be wire brushed to be free of slag to

exhibit a uniform and clean appearance.

e) Each layer of welding shall have a smooth appearance and shall be

free of weld spatter.

f) Extension bars, run-on and run-off plates shall be removed after

completion of welding. The end part of welding shall be flush ground
to a smooth finish.

Cleaning

All Slag and flux will be ground off or brush cleaned from each run before the
deposit of successive layers. The edges of the parts to be welded must be free
of rust, sand, tar, oil and grease.
4.6 Assembly and Alignment

a) In assembling and joining part of structural or built-up member, the

procedure and sequence of welding shall be maintained to avoid excessive
distortion and to minimize shrinkage stresses.

b) Members to be welded will be bought into correct alignment and set in

position by bolts, clamps, tack welds or other suitable means drying
welding. Suitable allowance shall be made for warp and shrinkage.

c) Members which are to be assembled and installed where accuracy of

dimensions, alignment or clearance is critical will be identified on the
shop drawing and should be pre-assembled (optional) at the shop. Error or
discrepancies shall be corrected before the members are delivered.

d) Distorted members can be straighten by use of flame heating in which

external force or jacking is applied on the member to correct the distortion
after being heated up.

The following shall be observed in the course of straightening:

a) Maximum temperature of heated area shall be around 650°C.

b) Avoid sudden rate of heating or cooling.

4.7 Non-destructive Testing (Optional)

a) For Butt Welds:

Radiographic and Ultrasonic Examination.

b) For Fillet Welds and Conner Welds.

Magnetic Particle Examination.

Generally only critical structural steel member will subject to NDT

examination. The quantum of examination in this case is 5% to 10% of each
examination.

Control and handling of Non-destructive Testing (NDT) shall adhere “Non-

Destructive Testing(NDT) Procedure ”.
5. QUALITY CONTROL & INSPECTION

5.1 The fabricator will maintain a quality control; program to extent deemed
necessary, which are normally required in the fabrication, assembly and
erection of structural steel.

5.2 When NDT is required, the process, extent technique and standard of
acceptance are clearly defined as per contract documents and though meeting
and discussion between client and fabricator.

All NDT to be carried out by an approved testing company.

5.3 Deviation from project specification, drawings or rule of codes and standards
is prohibited in principle. Circumstances arising, which indicate necessity for
deviation, must review by client and fabricator for solution.

5.4 QA/QC personal shall ensure that completed members should be free from
twists, bends and open joints, sharp kinks or bends.

5.5 On completion of fabrication, welding, NDT and galvanizing, all structure

steel work will be re-inspected, check for ID marking or tags, damaged
coatings etc prior to shipment.

5.6 Inspection

a) During the course of material receiving, preparation, fabrication and

welding, the Quality Control personnel will monitor and carry out in-
house inspection a all stage of fabrication works. The information obtained
will than be complied to prepare the following documentation:

• Incoming Quality Assurance (IQA) Inspection Report.

• Inspection Report (Dimension, Fit-up, welding and visual)

• Blasting and Painting Inspection Report.

• NDT Report (Prepare by third party)

 b) The Inspection extent range from the spot inspection, full inspection and
quantum of inspection from random to full quantity depend on fabricated
part function nature. This may be established by mutual agreement
between client and Dynaciate Engineering Sdn. Bhd. Generally the reports
for Inspection Report (Dimensional, Fit-up and Welding) and Galvanizing
Report are also prepared for key structural members only, although
inspections are carried out most other parts.

5.7 Inspection Process

6. NON CONFIRMING ITEM CONTROL

This is to establish guideline for identifying, evaluating, segregation and disposing of

non-conforming products defected.

a) Report of non-conformity

• All non-conformity items shall be identified and mark "HOLD" by the

QC

• The Inspection shall also complete the non-Conforming report forms

(NCR) indicating all pertinent details of non-conformity.

• The completed NCR shall submit to the QA manager for approval and
further action. The approved NCR shall distribute to production or
project supervisor to determine the disposition of non-conformity.

b) Remedy / Corrective Action

• The remedial action to be undertaken in order to eliminate the non-

conformity shall be proposed by receiver with appropriate
authorization.

c) Items requiring correction, rework, and repair, return shall be re-inspected by

the QA upon completion for compliance with governing acceptability criteria.
Upon receipt of satisfactory results of such inspection the QA Manager or
designated personnel shall authorize the removal of "HOLD" sticker. Items
considered not acceptable after correction, rework or repair, it shall be
properly marked and shall be removed or returned as soon as possible from
work site.