NEOM-11 Regional Infrastructure

Redco-ElSeif Contracting

Contract No. 4800000678

Contract Title Design, Build and Operate Precast Facilities

Work/Service Order No. 000

Work Order Title Main Contract

Inspection and Test Plan for Structural Steel Fabrication M/s Kirby
Document No. 11-640000-4800000678-RED-STR-ITP-000001_01
Document Revision History:

Revision Status Prepared by Checked by Approved by

Rev. Date
Description (Reason for Issue) (Name/Position) (Name/Position) (Name/Position)

Julasiz Ahiyal Mohammad Shannak Qaisar Maqsood

01 Issued for Review For Approval 09/07/2023
QC Supervisor QA/QC Manager Project Manager

Signatures:

Document Review Status Date: Name/Signature:

A - Work May Proceed

B - Incorporate Comments - Proceed
C - Revise & Re-submit. Do NOT proceed
D - Rejected
E - Review Not Required - Proceed

Electronic documents once printed, are uncontrolled and may become out-dated. Refer to Aconex for current revision

Template Reference: 11-000000-0000100854-BEC-DCC-TMP-000003_01

 KIRBY BUILDING SYSTEMS – KUWAIT REF. DOC. NO. : ITP/KBS-KW
Q P – QUALITY PLAN REVISION NO. : 07
INSPECTION AND TEST PLAN – STEEL EFF. DATE : 08.06.14
QA / QC DEPARTMENT. PAGE NO : 1 of 3
FABRICATION
(Internal use only)

CUSTOMER : REDCO EL SEIF CONTRACTING

COMPANY JOB No. : KW-21520
PROJECT NO. : P000180
PO Number : ESEC-PO-000006451

SHALL BE REVISED BASE ON CONTRACTOR / END USER’S COMMENTS

ISSUE PREPARED BY REVIEWED BY APPROVED DATE

01 KIRBY BUILDING CONTRACTING END USER 29.05.23

(For customer) SYSTEMS CO.

UNCONTROLLED COPY
It is computer generated documents; no signatures required

THESE ARE CONFIDENTIAL DOCUMENTS AND SHALL BE SUBMITTED ON CUSTOMER REQUEST.

Inspection and Test Plan
 KIRBY BUILDING SYSTEMS – KUWAIT REF. DOC. NO. : ITP/KBS-KW
Q P – QUALITY PLAN REVISION NO. : 07
INSPECTION AND TEST PLAN – STEEL FABRICATION EFF. DATE : 08.06.14
QA / QC DEPARTMENT. PAGE NO : 2 of 3
(Internal use only)
Inspection by
Kirby QC
Applicable Extent of

Remarks
Verifying

End User /
Inspection

Customer
Item Process Description Procedure KBS
Specification Inspection Document

/ TPI
Activity

TPI
Ref.

1.0 DOCUMENTATION
Welding
Welding procedures
1.1 Procedure
(WPS & PQR)
Specifications, Welding
WPS With
Procedure WPS With Procedures
Welding Repair AWS D 1.1 PQR &
1.2 Qualification PQR
Procedure WQR Will be H R R
Records, Procedures Welders
submitted for
Welder’s/Welding WQR Qualificatio
review
1.3 Operator’s n Records
Welders Certificates
Qualification
Records
2.0 RAW MATERIAL INSPECTION – Identification and Review of MTC – Reports
2.1 H. R. plates for Built Up ASTM A 572
sections Grade 50

The Material can be change to the equivalent or

2.2 H.R. Section A 572 Grade 50

2.3 Purlin coils (pre ASTM A 653 / Visual

galvanized) AS 1397 Gr 450 KBS QC -
Sizes, Thickness & Inspection
WI-01
Dimensions of of material
2.4 Equal Angles, Round A572 Gr 50, A Materials During Off

higher grade.
Bars & Square Tube 500 Grade C For Mill Test
& Review, loading
Receipt Certificates
Verification of &
2.5 Plain / Pre painted A653/ 792 Inspection of Material
Mill Test 100 %
Sheeting coils Grade 340(C2) of use H R R
Certificates (MTC) Review
2.6 H. S. Bolts A 325 Incoming
and
M. S. Bolts ISO 898-1 / Raw
BS EN10204-3.1 Verification
A 307 Materials
of MTCs.
H. S. & M. S. Nuts A 563/ ISO
898-2
H. S. & M. S. Washers F 436 (Type1)
2.7 Miscellaneous Kirby STD.
3.0 IN-PROCESS ACTIVITIES
As per KBSK Record Heat # / 100 % check KBS QC –
Manual Cast # Of or verification WI 05
Drawings As Material Used of cut sheet for - Product PPC
3.1 Material Preparation / H R R
per approved on Issued Cut tracking Heat Identification Issued
Identification
erection Sheet By P & I #s of material & Cut sheet
drawing C Dept. used Traceability

4.0 FABRICATION
Shear /Punch Fabricated P R
Dimensional 10 %
4.1 assemblies / structures As per KBSK KBS QC –
Checks Against
Manual & AWS WI 02 QC In House
Shop Fabrication H W
4.2 Build Up, Hot Rolled Kirby Factory Fabrication Inspection R
Drawings As per 100%
tolerances Control Reports
approved
4.3 Cold Form (Secondary’s MBMA, AISC Procedure P W
erection drawing 10 %
Members)
 KIRBY BUILDING SYSTEMS – KUWAIT REF. DOC. NO. : ITP/KBS-KW
Q P – QUALITY PLAN REVISION NO. : 07
NSPECTION AND TEST PLAN – STEEL FABRICATION EFF. DATE : 08.06.14
QA / QC DEPARTMENT. PAGE NO : 3 of 3
(Internal use only)

Inspection by
Kirby

Remarks
Applicable Extent of QC

End User /
Customer
Item Process Description Inspection Verifying K
Specification Inspection Procedure

/ TPI
Document

TPI
Activity B
s Ref. S
5.0 WELDING INSPECTION & NON-DESTRUCTIVE TESTING
Full Weld Visual inspection Visual Inspection 100% Welding Welding H W R
5.1 NDT- Butt Weld in flanges Map, Inspection
AWS D1.1 UT 5% Drawing Reports
and Webs H R R
5.2 Weld Map NDT
NDT- Fillet weld DP/MT 5% Testing UT Report
Repaired Weld defects (If Drawings As Procedure
5.3 per approved Visual Inspection 100% Note: NDT
Any) H W R
erection NDT may Inspection
NDT (if any) drawing UT 100% be Report
outsourced H R R
6.0 SURFACE PREPRATION & PAINTING
Surface preparation Inspect the Surface Surface
BU/ HR: Sa2.5 Surface Finish 100% Preparation Preparation &
Primer: Interseal1052 after cleaning & Painting H W R
6.1 @190µm SSPC VISUAL Painting Inspection
Top Coat: Interthane CHECK DFT 100 % Procedure Reports
990SG@50µm
Total: 240µm
ASTM Surface 100% Vendor
A123 Preparation Approved/ Galvanizing
6.2 Hot Dip Galvanizing
ASTM Visual Inspection Repair Inspection H R R
A780 DFT Check 50 % Procedure Reports
KBS QC QC
Engg
6.3 Final Visual Inspection Visual Inspection 100% – WI 02 Inspection H R R
Drawing
Reports
7.0 PACKING, LOADING AND SHIPPING

After completion of the

Random check

job, QC Dossier shall

be submitted to Cust.
Check KBS QC Complete
Loaded Truck &
7.1 Finished – WI QC Dossier
As per 2 to 3
Marking, Packing & Packing Product Packing, (Inspection
KBSK Photographs P R R
List, Handling & Shipment Handling, Loading & Testing
Manual taken per Truck
Loading & & Repots,
Load (With
Photographs Shipping Release
Touch up for
Control Notes)
damaged area)

P = PERFORM INSPECTION W = RANDOM WITNESS INSPECTION (up to 10%) R = REVIEW RECORDS

H = HOLD POINT C = CERTIFY / CERTIFICATION S = SURVEILLANCE, SW = SURVEILLANCE &
WITNESS A = APPROVAL, I = ISSUE, DP = Dye Penetrant Test, MT = Magnetic Particle Test, VT = Visual Inspection,
UT = Ultrasonic Testing,

NOTE: 1. Extent of Inspection is applicable for KIRBY QC Inspection only, for others on the random basis
2. TPI shall be appointed by Contractor/End user. TPI Painting Inspection shall be carried out after Topcoat.
3. Any inspection by TPI/Contractor/end user shall be carried out along with the manufacturing process at kirby premises.
KBS: Kirby Building Systems, Kuwait TPI: Third Party Inspection
Fabrication Welding Procedure
 SOP No. : QC – WI 02
REV. No. : 06
KIRBY BUILDING SYSTEMS – KUWAIT EFF. DATE : 02.08.22
FABRICATION-WELDING PROCEDURE Page No. : 2 of 6
Quality Control Department (Internal Use only)

TABLE OF CONTENTS

1.0 SCOPE

2.0 RESPONSIBILITIES

3.0 REFERENCE STANDARD

4.0 FABRICATION

5.0 FULL WELDING & NDT

6.0 COLD FORMS SECTIONS

7.0 QC TESTING & INSPECTION

8.0 RECORDS
 SOP No. : QC – WI 02
REV. No. : 06
KIRBY BUILDING SYSTEMS – KUWAIT EFF. DATE : 02.08.22
FABRICATION-WELDING PROCEDURE Page No. : 3 of 6
Quality Control Department (Internal Use only)

1.0 SCOPE:

The entire fabrication shall be carried out as per approved drawings, contractor specification, applicable
codes and standards for the project.

2.0 RESPONSIBILITES:

* The plant manager shall be responsible for execution and ensuring of all activities as per
specification.

* The shop floor foremen shall be responsible for carrying out all activities as per approved drawings,
specifications, procedure, engineering standards and good engineering practice.

* The Quality Control Manager shall be responsible for ensuring that all Quality Control, Welding,
NDT and Shop Inspection requirements are met as per Inspection and Test Plan.

3.0 REFERENCE STANDARD

 MBMA : Material Building Manufacturers Association

 AISC : American Institute of Steel Construction
 AWS D 1.1-2015: American Welding Society
 ASTM A6/6M - Specification for General requirement for rolled structural bars, plates, shapes &
sheet piling
 ASTM A 153 - Specification for Zinc coating (Hot-Dip) on iron and steel Hardware
 12-SAMSS-014
 Inspection and Test Plan (ITP)
 ASNT : American Society for Non-destructive Testing
 Kirby Approved WPS/PQR

4.0 FABRICATION:

The Pre Engineered Building members are composed mainly of the following types of structural
components:
* Built–up / Hot Rolled sections
* Cold forms (z & C forms)
* Cladding

4.1 BUILT–UP / Hot Rolled sections

B / U sections are used as primary or main structural framing members and are produced as per ITP. With
the help of three plate, I-sections are produced by the automatic submerged arc welding process.
Following manufacturing steps shall be followed while fabrication of Primary members (Beam, columns,
rafter etc..):

4.1.1 Shearing / Flame cutting/ Edge Preparation:

4.1.1.a) Shop drawings for each member of the building issued to Production & Inventory Control
Department by Engineering. These drawings are strictly in accordance with the design drawings
approved by client.

4.1.1.b) Production & Inventory control prepares material cut sheets showing the raw material
requirements and allocates the material for the job that is to be drawn from inventory.

4.1.1.c) Base on the material cut sheets and shop drawings, the shear department cut the flanges and
webs required for the B/U sections. Plates up to 12 mm thick are sheared and higher thickness plates are
cut by multi head automatic flame cutting machine.

4.1.1.d) The cut flange and web pieces are marked showing the respective piece mark number of the
member as per shop drawings.

4.1.1.e) Any edge preparation & bevel shall be made as per drawing or as per WPS. Any sheared edge or
gas cut edge shall be grinded off as per AWS requirements.
 SOP No. : QC – WI 02
REV. No. : 06
KIRBY BUILDING SYSTEMS – KUWAIT EFF. DATE : 02.08.22
FABRICATION-WELDING PROCEDURE Page No. : 4 of 6
Quality Control Department (Internal Use only)

4.1.1.f) The Heat number of plates used is transferred to the respective cut sheets and returned back to
Production & Inventory Control / QC department for records.

4.1.1.g) Part Mark number will be written on the sheared /flame cut pcs for the traceability by chalk.

4.1.1.h) HR members shall be cut, drill in beam line. Bend saw can be used for cut to the length.

4.1.2 Seam Welding

4.1.2.a) As the raw steel plates are in 6-meter lengths, flanges and webs that are longer than 6 meter must
be butt-welded to the required length. Seam welding is done online by the submerged arc welding
process.

4.1.2.b) All Butt joint shall be prepared as full penetration joints & shall follow AWS D1.1 requirement.

4.1.2.c) Welding shall be inspected by QC inspector and approved for further processing.

4.1.3 Hole punching/ Drilling:

4.1.3.a) Holes on flanges, connection plates, details and webs shall be punched online by punch press or
by CNC drilling machine to the specified pitch and gage. Kirby fabrication drawing shall be referred.

4.1.3.b) Now the flanges and webs are ready for welding to I-section on the CONRAC weld and are
stacked in the flange / web stacker for further processing.

4.1.3.c) Drilling of extra holes can be made offline for HR members (if not possible at beam line).

4.1.4 Conrac Weld:

4.1.4.a) Flanges and web are assembled on conrac assembly line and tack welded at front end, fed into
the CONRAC semi-automatic welding machine.

4.1.4.b) The conrac welding machine automatically centres the web with the flanges and applies flange
to web fillet weld continuously on one side of web along both edges. Selecting the weld parameters on
the control panel controls the size of the weld.

4.1.4.c) A continuous weld shall be applied on both side of web with flanges along the length of
member. Size of the weld shall be as per AWS D1.1. For second side fillet welding, the member is again
fed into the conrac machine. Single & Double side weld shall be selected as per weld map or as per
fabrication drawing.

4.1.4.d) The weld process used is submerged arc weld with all weld consumables and welding
parameters in accordance with company’s prepared WPS and PQR complying with AWS D1.1.

4.1.4.e) When fillet weld exceeds the maximum permissible size by conrac weld, the additional welding
is done at offline using squid mobile welding machine, LT7 etc.

4.1.5 Details:

4.1.5.a) The splice plates, clips, brackets, etc. that are to be welded to the Built-up members are produced
on separate production lines in accordance with the shop detail drawings. Hard punch stencilling shall be
done to traceability of Part Mark.

4.1.5.b) Preparation of bevel at required surface shall be addressed as per drawing or AWS D1.1. Bevel
can be made by using Manual cutting, Grinding, Gas Cutter or machining (whatever appropriate).

4.1.6 Assembly:

4.1.6.a) The applicable details are assembled to the built-up member by fabricators after the conrac weld.
These are tacks welded at the correct location as per shop drawings. MBMA & AISC tolerances shall be
followed for any built-up & HR assembly respectively.
 SOP No. : QC – WI 02
REV. No. : 06
KIRBY BUILDING SYSTEMS – KUWAIT EFF. DATE : 02.08.22
FABRICATION-WELDING PROCEDURE Page No. : 5 of 6
Quality Control Department (Internal Use only)

5.0 FULL WELDING & NDT:

5.1 All welding activities shall be performed according to the approved WPS (Kirby/customer) by Kirby
certified welders (as per AWS). Final welding shall be made by using FCAW process with 100% CO2 as
shielding gas.

5.2 Any multi pass welding shall be performed as per approved WPS. Each weld pass shall be cleaned
properly with the help of gauging machine, grinder, wire brush etc.

5.3 The full and final welding is done on all assembled components at welding area. The welding shall be
carried out as per approved WPS & weld map.

5.4 Any weld area missed out in conrac weld process, are completed and wherever required / necessary
back gauging / grinding is done to achieve full penetration welds at all butt welds / joints.

5.5 All welds are cleaned from slag, flux and other extraneous matter.

5.6 Any welding activities shall be carried out enclosed area where external air & debris shall not affect the
quality of weld. A proper shad shall be maintained if welding is carried out in open area. Air ventilation is
also required.

5.7 NDT shall be performed by certified NDT Level II technician. The frequency of NDT shall be as per
ITP. The selection of pcs shall be made by Kirby QC.

6.0 COLD FORMS SECTION:

The following is a brief outline of the manufacturing process for the above types of cold form members:

6.1 Zee & Cee Sections

6.1.1The coils are mounted on de-coiler of the holes punching and cut-to-length line and flat strips with
punched holes are cut to the required length as per cut sheet / shop drawings.

6.1.2 Coil card shall be maintained for material traceability.

6.1.3 Bundles shall be made for maximum 2MT each. Different length of purlins shall be bundled in such a
matter to handle the bundle in proper condition.

6.2 Press-braking for C form:

6.2.1 The cut to length pieces is transferred to the Press-Brake station & pressed to the required profile with
required degree slope as per shop drawings.

6.2.2 QC inspection carried out randomly for dimensions and profile and released for packing and shipment

6.3 Sandwich Panels: (If supplied by Kirby for project)

6.3.1 Sandwich panels shall be manufactured by the press injection method to produce a rigid polyurethane
core between exterior facings. The manufacturing Process shall be carefully controlled with steel facings
maintained at around 40 o C during the injection process to ensure proper reaction and adhesion.

6.3.2 The pressure on the modules shall not be released till completion of reaction. The exterior Top facing
of sandwich panels for the project building is of KR Profile, which is manufactured by feeding into profile
forming (Kirby profile of 1000mm. covering width) mill.

6.3.3 Standard panels shall have an approximate total density of 40kg / m 3, with a heat Transmission value
of 0.02 Watt / m2. The mechanical properties of the foam shall be as per chemical supplier
recommendations.

6.3.3 Surface of SWP shall be cleaned properly & shall be free from any rust, dust, oil or any other foreign
particles.

6.3.4 Bundle of SWP shall be wrapped with polyethylene film in order to prevent any movement &
damages. Wrapping belt shall have cotton/ paper L bows in order to protect the edge of contact.
 SOP No. : QC – WI 02
REV. No. : 06
KIRBY BUILDING SYSTEMS – KUWAIT EFF. DATE : 02.08.22
FABRICATION-WELDING PROCEDURE Page No. : 6 of 6
Quality Control Department (Internal Use only)

7.0 QC TESTING & INSPECTION:

7.1 Upon completion of fabrication of black steel, a full QC inspection & NDT shall be made in
accordance with the approved Inspection and Test Plan (ITP).

7.2 All stages of inspection with the frequency mentioned in ITP shall be followed.

7.3 QC shall inform the customer for any inspection in advance (as per ITP-if any).

7.4 The cut flanges and webs are stage inspected by QC for random visual and dimensional inspection and
approved for further processing

7.4 Fabrication and welding shall be made by Kirby approved fabricator & welder. QC shall arrange visual,
dimensional inspection with reference of international standard (clause 3.0). Daily inspection reports shall
be prepared & maintained.

7.5 Welding inspection shall be carried out by certified welding inspector or experienced welding inspector
(under the supervision of certified welding inspector). Project specification or AWS D1.1 Table 8.1 should
be referred.

7.6. NDT reports shall be reviewed & recorded as per ITP.

7.7 All inspection reports can be shared to customer upon request (after completion of phase or building).

8.0 ATTACHMENTS:

Fitting Inspection Report

Welding Inspection Report
 Master List of Welding Procedure Specifications/ Weld map

QC-WPS-10(R09- 22.07.20)
SN WPS Rev Date PQR Process Joint Designation Process Remarks Application NOTES Special Note
1 KBS-WPS Weld Map 8 21.07.16 - - All All - Full Welding - -
2 KBS-WPS FCAW-57 6 09.07.20 KBS-PQR FCAW-57/2009 Single V Butt Joint FCAW BG Full Welding 3mm-40mm CJP
3 KBS-WPS FCAW-58 2 09.07.20 KBS-PQR FCAW-57/2010 Single V Butt Joint FCAW T & Corner Joints Full Welding 3mm-40mm CJP
4 KBS-WPS FCAW-59 2 09.07.20 KBS-PQR Prequalified Fillet Weld T Joint FCAW Clips & child part Full Welding Unlimited PJP
5 KBS-WPS SAW- 58 2 09.07.20 KBS-PQR SAW- 58 Single V Butt Joint SAW - Offline, LT7 Unlimited CJP
6 KBS-WPS SAW- 59 2 09.07.20 KBS-PQR SAW- 59 Fillet Weld T Joint SAW - Conrac 3-12mm PJP, T JOINTS
7 KBS-WPS SAW-60 3 09.07.20 KBS-PQR SAW-60 Square Groove Butt Joint SAW, FCAW - Flange line, Offline Unlimited CJP
8 KBS-WPS SMAW-59 4 22.07.20 KBS-PQR SMAW-59 Square Groove Butt Joint SMAW Tack weld Fitting Line Unlimited PJP

Note:
1. Production materials shall be as per approved drawings.
2. All the material used for welding are from ASTM A572 Grade 50.

Prepared by : Certified by
Pradyumn Kumar (QA/QC Manager)
Piychai Selvaraj Certified Welding Inspector-AWS
Certified Welding Inspector-AWS
 Document details (for Vendor use only)
Vendor Document No. VD-V001-KBS-PRO-0001 Vendor Rev. B
 WELDING PROCEDURE SPECIFICATIONS (WPS)

Company Name : Kirby Building Systems-Kuwait Identification # : KBS - WPS - FCAW # 57

Welding Process(es) : FCAW ( Flux cored Arc weld ) Revision : 6 Date: 09-Jul-20 By : Pradyumn Kumar
Supporting PQR No.(s) : KBS - PQR - FCAW # 57 /2009 Authorized by : Pradyumn Kumar Date : May 09-Jul-20
18, 2012
Code: AWS D1.1-2015 Type - Manual Semi - Automatic x
- Machine - Automatic

JOINT DESIGN USED POSITION

Type : Butt joint
Single Double welded : x Position of Groove 1G Fillet 1F
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening R = 0 - 3 mm Rt Face Dim,n.f = 0 - 3 mm.
Groove Angle 60° [+10°/-5°] Radius(J-U) None ELECTRICAL CHARACTERISTICS
Backgouging: Yes x No Method : Grinding Transfer Mode (GMAW): N/A
Short-circuiting Globular Spray X
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 / ASTM A 572 Other:
Type or Grade: Grade 50 / Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove / Fillet : T1 = T2 = 3.5 ~ 40 mm for Size N/A
Groove & for Fillet: all sizes Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS A5.20 Stringer or Weave Bead Stringer Bead
AWS Classification E 71 T - 1 Multi-pass or single Pass (per side) Multi Passes
Manufacturer/Trade Name Tien Tai Number of Eectrodes Single Electrode
Electrode Spacing: Longitudinal N/A
SHIELDING Lateral N/A
Flux N/A Gas C02 Angle N/A
Composition 100% Contact Tube to Work Distance 2 cms ~ 2.5 cm
Electrode - Flux (Class) Flow Rate L/M 20 / 22 Peening N/A
N/A Gas Cup Size N/A Interpass Cleaning Wire Brush / Grinding

PREHEAT Groove Perparation

Joint Base metal thickness Allowed
Preheat Temp, Min: See Note Below Welding Tolerance Gas
Designat Root Welding
Process Shielding
ion Opening As Positions
Interpass Temp, Min: See Note Below T1 T2 As Fit Up
detailed

Min Preheat / Interpass Temprature

20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC R=0-3 +2,-0 +2,-3
FCAW B-U2-GF U - f=0 to 6 +2,-0 No Limit ALL CO2
65mm ≤ T ˃ 38mm is 66 ˚C & T ˃65mm is 110 ˚C a=60˚ -10˚,-5˚ -10˚,-5˚
POSTWELD HEAT TREATMENT N/A
Welding Procedure
Pass Filler Metal Current Joint Details
or Wire feed Trav Gas B - U2 - GF
Weld Pro- Dia. Type & Speed Speed flow
Layer cess Class mm. Polarity Amps inches/Min Volts Inch/min Ltr./min. Back-
1st. Side gouge
1 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22
2 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22
3 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22
4 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22
5 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22
R = 0 ~ 3 mm
To achieve complete penetration, second side shall be ground to sound metal prior to start weld on second side f = 0 ~ 3 mm
2nd. Side a = 60° [+10° / - 5°]
1 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26.04 - 29.96 16 - 26 20-22

Prepared by : Certified by Reviewed by : Approved by :

Piychai Selvaraj Pradyumn Kumar (QA/QC Manager)

Certified Welding Inspector-AWS Certified Welding Inspector-AWS
Kirby Building Systems - Kuwait Kirby Building Systems - Kuwait
 PROCEDURE QUALIFICATION RECORD ( PQR ) Yes X
QUALIFIED BY TESTING Yes X
(As per AWS D1.1 - 2015)

Supporting PQR No.: # : KBS - PQR - FCAW # 57 / 2009.

Company Name : Kirby Building Systems-Kuwait Revision : 1 Date: 01-Dec-18 By : Pradyumn Kumar
Welding Process(es) : FCAW ( Flux cored Arc weld ) Authorized by : Pradyumn Kumar Date : May 11, 2009.
01-Dec-18
Code: AWS D1.1-2015 Type - Manual Semi - Automatic x
- Machine - Automatic

JOINT DESIGN USED POSITION

Type : Butt joint
Single Double welded : x Position of Groove 1G Fillet -
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening 2 mm Rt Face Dim,n. f = 2 mm.
Groove Angle 60° Radius(J-U) None ELECTRICAL CHARACTERISTICS
Backgouging: Yes x No Method Ground Transfer Mode (GMAW): N/A
Short-circuiting Globular Spray X
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 / ASTM A 572 Other:
Type or Grade: Grade 50 / Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove : T1 = T2 = 3.5 ~ 40 mm for Size N/A
Diameter (Pipe) N/A Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS A5.20 Stringer or Weave Bead Stringer Bead
AWS Classification E 71 T - 1 Multi-pass or single Pass (per side) Multi Pass
Manufacturer/Trade Name Tien Tai Number of Eectrodes Single Electrode
Electrode Spacing: Longitudinal N/A
SHIELDING Lateral N/A
Flux N/A Gas C02 Angle N/A
Composition 100% Contact Tube to Work Distance 2 cm.
Electrode - Flux (Class) Flow Rate L/M 20 Peening N/A
N/A Gas Cup Size N/A Interpass Cleaning Ground and wire brushed

PREHEAT POSTWELD HEAT TREATMENT

Preheat Temp, Min: 20°C Temp: Min N/A
Interpass Temp,Min: 220°C Max: 225°C Temp: Max. N/A

Welding Procedure
Filler Metal Current
Pass Joint Details
or Wire feed Trav Gas B - L2 - F
Weld Pro- Dia. Type & Speed Speed flow Back-
Layer cess Class mm. Polarity Amps inches/Min Volts Inch/min Ltr./min. gouge
1st. Side
1 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20
2 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20
3 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20 R = 2mm.
4 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20 f = 2mm
5 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20 a = 60
To achieve complete penetration, second side shall be ground
2nd. Side to sound metal prior to start weld on second side
1 FCAW E71T - 1 1.6 DCEP 280 260 28 21 20 T1 = T2 = 20 mm.
Complete Joint Penetration
Form E-1 (Front)
Prepared by : Certified by Reviewed by : Approved by :

Piychai Selvaraj Pradyumn Kumar

Certified Welding Inspector-AWS QA/QC Manager
Kirby Building Systems - Kuwait Kirby Building Systems - Kuwait
 WELDING PROCEDURE SPECIFICATIONS (WPS)

Company Name : Kirby Building Systems-Kuwait Identification # : KBS - WPS - FCAW # 58

Welding Process(es) : FCAW ( Flux cored Arc weld ) Revision : 2 Date: 09.07.20 By : Pradyumn Kumar
Supporting PQR No.(s) : KBS - PQR - FCAW # 57 Authorized by : Pradyumn Kumar Date : May 18, 2012
09.07.20
Code: AWS D1.1-2015 Type - Manual Semi - Automatic x
- Machine - Automatic

JOINT DESIGN USED POSITION

Type : Single Bevel Groove (BUTT, T & C)
Single Double welded : x Position of Groove 1G Fillet 1F
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening R = 0 - 3 mm Rt Face Dim,f = 0 -3 mm
Groove Angle 45° [+10°/-5°] Radius(J-U) None ELECTRICAL CHARACTERISTICS
Backgouging: Yes x No Method : Grinding Transfer Mode (GMAW): N/A
Short-circuiting Globular Spray X
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 ASTM A 572 Other:
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove / Fillet : T1 = T2 = 3.5 ~ 38 mm for Size N/A
Groove & for Fillet: all sizes Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS A5.20 Stringer or Weave Bead Either
AWS Classification E 71 T - 1 Multi-pass or single Pass (per side) Either
Manufacturer/Trade Name Tien Tai Number of Eectrodes Single Electrode
Electrode Spacing: Longitudinal N/A
SHIELDING Lateral N/A
Flux N/A Gas C02 Angle N/A
Composition 100% Contact Tube to Work Distance 20 mm ~ 25 mm
Electrode - Flux (Class) Flow Rate L/M 20 / 22 Peening N/A
N/A Gas Cup Size N/A Interpass Cleaning Wire Brush / Grinding

PREHEAT Groove Perparation

Base metal thickness Allowed Gas
Preheat Temp, Min: See Note Below Joint Root Tolerance
Welding Process Welding Shieldi
Designation Openin As Positions ng
Interpass Temp, Min: See Note Below T1 T2 g As Fit Up
detailed
Min Preheat / Interpass Temprature R=0-3 +2,-0 +2,-3
FCAW TC-U4b-GF U U f=0 to 3 +2,-0 No Limit ALL CO2
20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC a=45˚ -10˚,-5˚ -10˚,-5˚
65mm ≤ T ˃ 38mm is 66 ˚C & T ˃65mm is 110 ˚C
POSTWELD HEAT TREATMENT N/A
Welding Procedure Joint Details (TC-U4b-GF)
Filler Metal Current Single Bevel Groove Joint Weld(4)

Pass Wire feed Trav Gas T-Joint (T)

Weld or Pro- Dia. Type & Speed Volts Speed flow Corner Joint ( C)

Layer cess Class mm. Polarity Amps inches/Min Inch/min Ltr./min.

1st. Side
1 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26 - 30 16 - 26 20-22
2 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26 - 30 16 - 26 20-22
To achieve complete penetration, second side shall be ground
2nd. Side to sound metal prior to start weld on second side
1 FCAW E71T - 1 1.6 DCEP 252 - 308 234 - 286 26 - 30 16 - 26 20-22

Prepared by : Certified by Reviewed by : Approved by :

Salva raj Pradyumn Kumar

Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait AWS Certified Inspector
 WELDING PROCEDURE SPECIFICATIONS (WPS)

Company Name : Kirby Building Systems-Kuwait Identification # : KBS - WPS - FCAW # 59

Welding Process(es) : FCAW ( Flux cored Arc weld ) Revision : 2 Date: 09-Jul-20 By : Pradyumn Kumar
Supporting PQR No.(s) : Pre-Qualified as Per AWS D 1.1 Authorized by : Pradyumn Kumar Date : May 18, 2012
09-Jul-20
Code: AWS D1.1-2015 Type - Manual Semi - Automatic x
- Machine - Automatic

JOINT DESIGN USED POSITION

Type : Fillet Weld T- Joint
Single X Double welded : Position of Groove All Fillet All
Backing : Yes X No : X Vertical Progression: Up Down N/A
Backing Material : None
Root Opening R = 0 - 5 mm Rt Face Dim,f = N/A
Groove Angle N/A Radius(J-U) N/A ELECTRICAL CHARACTERISTICS
Backgouging: Yes No X Method : N/A Transfer Mode (GMAW): N/A
Short-circuiting Globular X Spray
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 ASTM A 572 Other:
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove / Fillet : T1 = T2 <75 mm Size N/A
Groove & for Fillet: all sizes Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS A5.20 Stringer or Weave Bead Either
AWS Classification E 71 T - 1 Multi-pass or single Pass (per side) Either
Number of Eectrodes Single Electrode
SHIELDING Electrode Spacing: Longitudinal N/A
Flux N/A Gas C02 Lateral N/A
Composition 100% Angle N/A
Electrode - Flux (Class) Flow Rate L/M 20 / 22 Contact Tube to Work Distance 20 mm ~ 25 mm
N/A Gas Cup Size N/A Peening N/A
Interpass Cleaning Wire Brush / Grinding

PREHEAT Minimum Fillet weld Size (AWS D1.1 Table 5.8)

Preheat Temp, Min: See Note Below Base Metal Thickness T(mm) S* * Weld size need not exceed the

Interpass Temp, Min: See Note Below Max: 315°C T= Thickness of T≤6 3 thickness of the thinner part joined.
thinner part joined
Min Preheat / Interpass Temprature for T ≤ 38 min is 10ºC 6 ˂T ≤ 12 5

T ˃38mm to 63mm is 66 ˚C & T ˃63mm is 110 ˚C Multi pass may be 12 ˂T ≤ 20 6

used 20 ˂T 8
POSTWELD HEAT TREATMENT N/A * Maximum single pass fillet size of weld shall be 8mm.
Welding Procedure Joint Details
Filler Metal Current T-Joint (T)

Pass Wire feed Trav Gas

Weld or Pro- Dia. Type & Speed Volts Speed flow
Layer cess Class mm. Polarity Amps inches/Min Inch/min Ltr./min.
1st. Side
1 FCAW E71T - 1 1.6 DCEP 261 ~ 319 250 ~ 275 27 ~31 20 ~ 22 20~22
TC-F12-GF

Prepared by : Certified by Reviewed by : Approved by :

Salva raj Pradyumn Kumar

Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait AWS Certified Inspector
 WELDING PROCEDURE SPECIFICATIONS (WPS)
PRE QUALIFICATION

Company Name : Kirby Building Systems-Kuwait Identification # : KBS - WPS - SAW # 58 / 2009.
Welding Process(es) : SAW ( Submerged Arc weld ) Revision : 2 Date: 09-Jul-20 By : Pradyumn Kumar
Supporting PQR No.(s) : KBS - PQR - SAW # 58 / 2009. Authorized by : Pradyumn Kumar Date : 09-Jul-20
May 10, 2009.
Reference Code: AWS D1.1-2006 Type - Manual Semi - Automatic
- Machine x - Automatic

JOINT DESIGN USED POSITION

Type : Butt joint
Single Double welded : x Position of Groove 1G Fillet 1F
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening: 0 mm. [+1.5mm/-0] Rt Face Dimn. f = 6 mm. [+/- 1.5] ELECTRICAL CHARACTERISTICS
Groove Angle 60° [+10°/-5°] Radius(J-U) None
Backgouging: Yes x No Method : Grinding Transfer Mode (GMAW): N/A
Short-circuiting Globular Spray
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 / ASTM A 572 Other:
Type or Grade: Grade 50 / Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove / Fillet : T1 = T2 = 3.0 ~ 40 mm for Groove Size N/A
Diameter (Pipe) = > 24" NPS & for Fillet: all sizes Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS A5.17 Stringer or Weave Bead Stringer Bead
AWS Classification EM 12K Multi-pass or single Pass (per side) Muliple pass
SHIELDING Number of Eectrodes Single Electrode
Flux N/A Gas N/A Electrode Spacing: Longitudinal N/A
Composition N/A Lateral N/A
Electrode - Flux (Class) Flow Rate L/M N/A Angle N/A
F7A2 EM 12K Gas Cup Size N/A Contact Tube to Work Distance 2 cms ~ 2.5 cm
PREHEAT Peening N/A
Preheat Temp, Min: 20°C Interpass Cleaning Wire Brush / Grinding, for slag removal
Interpass Temp,Min: 220°C Max: 225°C

Min Preheat / Interpass Temprature POSTWELD HEAT TREATMENT

20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC Temp: Min N/A
65mm ≤ T ˃ 38mm is 66 ˚C & T ˃65mm is 110 ˚C Temp: Max. N/A

Welding Procedure
Filler Metal Current Joint Details
Pass B - L1b - S
or Wire Feed Travel Back-
Weld Pro- Dia. Type & Speed Speed gouge
Layer cess Class mm. Polarity Amps Volts Inches/Min Inches/Min
1st. Side
1 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33
2 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33
3 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33 R = 0 [+1.5 mm / - 0]
4 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33 f = 6 mm. Max
Achieved complete penetration joint by grinding second a = 60°
2nd. Side side to the sound metal prior to start weld on second side
1 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33 Complete Joint Penetration
2 SAW EM 12K 4 DCEP 522 ~638 27.9 ~ 32.1 58 ~ 70 27 ~ 33
Form E-1 (Front)
Prepared by : Certified by Reviewed by : Approved by :

Salva Raj Pradyumn Kumar

Sr. Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait Kirby Building Systems - Kuwait
 WELDING PROCEDURE SPECIFICATIONS (WPS)
(Qualified by Testing)

Company Name : Kirby Building Systems-Kuwait Identification # : KBS - WPS - SAW [Conrac] # 59/2009
Welding Process(es) : SAW ( Submerged Arc weld ) Revision : 2 Date: 09-Jul-20 By : Pradyumn Kumar
Supporting PQR No.(s) : KBS - PQR - SAW[Conrac] # 59/2009 Authorized by : M.
Pradyumn
Saleem Wahab
Kumar Date : 09-Jul-20
Reference Code: AWS D1.1-2015 Type - Manual Semi - Automatic
- Machine x - Automatic

JOINT DESIGN USED POSITION

Type : Fillet Weld
Single Double welded : Position of Groove Fillet 2F
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening 0 mm [+ / -0] Rt Face Dim,n. f = Square ELECTRICAL CHARACTERISTICS
Groove Angle N/A Radius(J-U) None Transfer Mode (GMAW): N/A
Backgouging: Yes No x Method : N/A Short-circuiting Globular Spray
Current: AC DCEP x DCEN Pulsed
BASE METALS Other:
Material Spec: ASTM A 572 ASTM A 572
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness: Groove / Fillet T1 = T2 = 3.5 ~ Unlimited/ 2 Size N/A
Max. 6mm Fillet & Smaller Type N/A
Diameter (Pipe) N/A
FILLER METALS TECHNIQUE
AWS Specifications AWS A5.17 Stringer or Weave Bead Stringer Bead
AWS Classification EM 12K Multi-pass or single Pass (per side) Single pass
SHIELDING Gas N/A Number of Eectrodes 2 in 1 Head
Flux N/A Composition N/A Electrode Spacing: Longitudinal 9 mm
Electrode - Flux (Class) Flow Rate L/M N/A Lateral N/A
F7A2 EM 12K Gas Cup Size N/A Angle 45°
Contact Tube to Work Distance 2 cms ~ 2.5 cm
PREHEAT Peening N/A
Preheat Temp, Min: See Note Below Interpass Cleaning N/A
Interpass Temp, Min: See Note Below
Min Preheat / Interpass Temprature
20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC
65mm ≤ T ˃ 38mm is 66 ˚C & T ˃65mm is 110 ˚C
POSTWELD HEAT TREATMENT N/A

Welding Procedure

Pass Filler Metal Current Joint Details

OR Wire Feed Travel
Weld Pro- Dia. Type & Speed Speed
Layer cess Class mm. Polarity Amps Volts Inches/Min Inches/Min

1 SAW EM 12k 1.6 DCEP 585~ 715 25 ~ 29 122 ~ 148 59-71

Partial Joint Penetration (PJP)

Prepared by : Certified by Reviewed by : Approved by :

Pradyumn Kumar
QA / QC Manager Welding Inspector
Kirby Building Systems - Kuwait Kirby Building Systems - Kuwait
 WELDING PROCEDURE QUALIFICATION RECORD (PQR)
QUALIFIED BY TESTING

Identification # : KBS - PQR - SAW[Conrac] # 59/2009

Company Name : Kirby Building Systems-Kuwait Revision : 0 Date: 10.05.09 By : Pradyumn Kumar
Welding Process(es) : SAW ( Submerged Arc weld ) Authorized by : M.
Pradyumn
Saleem Wahab
Kumar Date : 10.05.09
Reference Code: AWS D1.1-2006 Type - Manual Semi - Automatic
- Machine x - Automatic
JOINT DESIGN USED POSITION
Type : Fillet Weld
Single X Double welded : Position of Groove Fillet 2F
Backing : Yes No : x Vertical Progression: Up Down N/A
Backing Material : None
Root Opening 0 mm Rt Face Dim,n. f = Square ELECTRICAL CHARACTERISTICS
Groove Angle N/A Radius(J-U) None Transfer Mode (GMAW): N/A
Backgouging: Yes No x Method : N/A Short-circuiting Globular Spray
Current: AC DCEP x DCEN Pulsed
BASE METALS Other:
Material Spec: ASTM A 572
Type or Grade: Grade 50 Tungsten Electrode (GTAW):
Thickness: Fillet : T1 = 10 mm & T2 = 12 mm Size N/A
Diameter (Pipe) Type N/A
FILLER METALS
AWS Specifications AWS A5.17 TECHNIQUE
AWS Classification EM 12K Stringer or Weave Bead Stringer Bead
SHIELDING Gas N/A Multi-pass or single Pass (per side) Single pass
Flux N/A Composition N/A Number of Eectrodes 2 in 1 Head
Electrode - Flux (Class) Flow Rate L/M N/A Electrode Spacing: Longitudinal 9 mm
F 7A2 EM 12K Gas Cup Size N/A Lateral N/A
Angle 45°
PREHEAT Contact Tube to Work Distance 2 cms.
Preheat Temp: 20ºC Peening N/A
Interpass Temp. : 215ºC Max. 225ºC Interpass Cleaning N/A

POSTWELD HEAT TREATMENT N/A

Welding Procedure
Pass Filler Metal Current Joint Details
OR Wire Feed Travel B - L1a - F
Weld Pro- Dia. Type & Speed Speed
Layer cess Class mm. Polarity Amps Volts Inches/Min Inches/Min

1 SAW EM 12k 1.6 DCEP 650 27 135 65

T1 = 10 mm. & T2 = 12 mm, R=0

Partial Joint Penetration (PJP)
Form E-1 (Front)
Prepared by : Certified by Reviewed by : Approved by :

M. Saleem Wahab AWS Certified

QA / QC Manager Welding Inspector
Kirby Building Systems - Kuwait Kirby Building Systems - Kuwait
 WELDING PROCEDURE SPECIFICATIONS (WPS)
PRE QUALIFICATION

Identification # : KBS - WPS - SAW - 60

Company Name : Kirby Building Systems-Kuwait Revision : 3 Date: 09-Jul-20 By : Pradyumn Kumar
Welding Process(es) : SAW, FCAW Authorized by : Pradyumn Kumar Date : 09-Jul-20
Supporting PQR No.(s) : KBS - PQR - SAW - 60 Type - Manual Semi - Automatic X
Welding Code: AWS D1.1-2015 - Machine X - Automatic

Type : Squre Groove Butt joint POSITION

Single Double welded : x Position of Groove 1G Fillet N/A
Backing : Yes No : x Vertical Progression: Up Down
Backing Material : Flux / Weld Metal
Root Opening R = 0 - 2 mm Rt Face Dim,n. f = 0 - 3 mm.
Groove Angle N/A Radius(J-U) N/A ELECTRICAL CHARACTERISTICS
Backgouging: Yes x No Method : Arc Gouging / Grinding Transfer Mode (GMAW): N/A
Short-circuiting Globular X Spray
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 ASTM A 572 Other:
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove: 3 ~ 24mm Size N/A
Fillet : N/A Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS 5.17 (SAW) AWS 5.20 (FCAW) Stringer or Weave Bead Either
AWS Classification EM 12 K (SAW) E71 T-1 (FCAW) Multi-pass or single Pass (per side) Either
Manufacturer/Trade Name Tien Tai Number of Eectrodes Single Electrode
Electrode Spacing: Longitudinal N/A
SHIELDING Lateral N/A
Gas Co2 Angle N/A
Flux Composition 100% Contact Tube to Work Distance 19mm -25 mm
Electrode - Flux (Class) F7A2EM12K Flow Rate L/M 92-172.5 CFH 3 Peening N/A
Gas Cup Size 16mm Interpass Cleaning Brushing/Grinding
Manufacturer/Tra Tien
de Name Tai

PREHEAT Base metal Groove Perparation

Joint Allowed
Welding thickness
Preheat Temp, Min: See Note Below Designati Tolerance Welding Notes
Process Root
on As As Fit Positions
Interpass Temp, Min: See Note Below T1 T2 Opening
detailed Up
Min Preheat / Interpass Temprature SAW B-L1-S 12(max) - R=0 ±0 +2, -0 F Side1
20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC FCAW B-L1b-GF 10(Max) - R=0-3 +2, -0 +2, -3 ALL Side2
65mm ≤ T ˃ 38mm is 66 ˚C & T ˃65mm is 110 ˚C

POSTWELD HEAT TREATMENT NA

Welding Procedure

Pass Filler Metal Current Joint Details

or Wire Feed Travel B - L1a-S (SAW), B-L1b-F (FCAW)
Others

Weld Pro- Dia. Type & Speed Speed

Layer cess Class mm. Polarity Amps Volts Inches/Min Inches/Min

1 SAW EM12K 4.0 DCEP 522 - 638 27.9 - 32.1 58 70 27 - 33 Side1

2 FCAW E71T-1 1.6 DCEP 252 - 308 26.1 - 29.9 234 - 286 16- 26 Side2
(repair) Complete Joint Penetration ( CJP )
Form E-1 (Front)
Prepared by : Certified by Reviewed by : Approved by :

Salva raj Pradyumn Kumar

Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait AWS Certified Inspector
 PROCEDURE QUALIFICATION RECORD ( PQR )
QUALIFIED BY TESTING

Identification # : KBS - PQR - SAW - 60

Company Name : Kirby Building Systems-Kuwait Authorized by :0 Pradyumn 18.06.14
Date: Kumar By : Pradyumn Kumar
Welding Process(es) : SAW, FCAW Authorized by : M.
Pradyumn
Saleem Wahab
Kumar Date : 18.06.14
Welding Code: AWS D1.1-2015 Type - Manual Semi - Automatic X
- Machine X - Automatic
Type : Butt joint POSITION
Single Double welded : x Position of Groove 1G Fillet N/A
Backing : Yes No : x Vertical Progression: Up Down
Backing Material : Flux / Weld Metal
Root Opening R = 2 mm Rt Face Dim,n. f = 2 mm.
Groove Angle N/A Radius(J-U) N/A ELECTRICAL CHARACTERISTICS
Backgouging: Yes x No Method : Arc Gouging / Grinding Transfer Mode (GMAW): N/A
Short-circuiting Globular Spray X
BASE METALS Current: AC DCEP x DCEN Pulsed
Material Spec: ASTM A 572 ASTM A 572 Other:
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : Groove: T1=T2=12 mm Size N/A
Fillet : N/A Type N/A

FILLER METALS TECHNIQUE

AWS Specifications AWS 5.17 (SAW) AWS 5.20 (FCAW) Stringer or Weave Bead Either
AWS Classification EM 12 K (SAW) E71 T-1 (FCAW) Multi-pass or single Pass (per side) Either
Manufacturer/Trade Name Tien Tai Number of Eectrodes Single Electrode
Electrode Spacing: Longitudinal N/A
SHIELDING Lateral N/A
Flux Gas Co2 Angle N/A
Electrode - Flux (Class) F7A2EM12K Composition 100% Contact Tube to Work Distance 21 mm
Flow Rate L/M 115 CFH Peening N/A
Manufacturer Tien Gas Cup Size 16mm Interpass Cleaning Brushing/Grinding
/Trade Name Tai
PREHEAT POSTWELD HEAT TREATMENT
Preheat Temp, Min: 20°C Temp. Min. : N/A
Interpass Temp,Min: 220°C Max: 225°C Temp. Max. : N/A

Welding Procedure
Pass Filler Metal Current Joint Details
or Wire Feed Travel B - L1a-S (SAW), B-L1b-F (FCAW)
Weld Pro- Dia. Type & Speed Speed Others
Layer cess Class mm. Polarity Amps Volts Inches/Min Inches/Min

1 SAW EM12K 4.0 DCEP 580 30 64 30 Side1

2 FCAW E71T-1 1.6 DCEP 280 28 260 21 Side2
3 FCAW E71T-1 1.6 DCEP 280 28 260 21 Side2 Complete Joint Penetration ( CJP )
Form E-1 (Front)
Prepared by : Certified by Reviewed by : Approved by :

Salva raj Pradyumn Kumar

Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait AWS Certified Inspector
 WELDING PROCEDURE SPECIFICATIONS (WPS)

Identification # : KBS - WPS - SMAW - 59 / 2009

Company Name : Kirby Building Systems-Kuwait Revision : 4 Date: 22-Jul-20 By : Pradyumn Kumar
Welding Process(es) : SMAW (Shielded Metal Arc Weld) Authorized by : Pradyumn Kumar Date : 22-Jul-20
Supporting PQR No.(s) : KBS - PQR - SMAW - 59 / 2009 Type - Manual X Semi - Automatic
Welding Code: AWS D1.1-2015 - Machine - Automatic

POSITION
Type : Fillet Weld (T- Joint & Corner Joint) Position of Groove 1G Fillet ALL
Vertical Progression: Up Down
Single X Double welded :
Backing : Yes No : x
Backing Material : Weld Metal ELECTRICAL CHARACTERISTICS
Root Opening R = 0-3 mm Rt Face Dim,n. 0-3 mm Transfer Mode (GMAW): N/A
Groove Angle 60⁰[+10⁰/-5⁰] Radius(J-U) N/A Short-circuiting Globular Pulsed Spray

Backgouging: Yes NO X Method : N/A Current: AC DC X

Polarity EP X EN
BASE METALS Other:
Material Spec: ASTM A 572 ASTM A 572
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : T1= T2 = 3.5 ~ Unlimited Size N/A Type N/A
Groove / Fillet : N/A
TECHNIQUE
FILLER METALS Stringer or Weave Bead Either
AWS Specifications AWS 5.1 Multi-pass or single Pass (per side) Multi Pass
AWS Classification E7018 Number of Eectrodes Single Electrode
Manufacturer/Trade Name Supron Electrode Spacing: Longitudinal N/A
Lateral N/A Angle N/A
SHIELDING Contact Tube to Work Distance N/A
Peening / Interpass Cleaning N/A
Flux N/A Gas N/A N/A
Composition N/A POSTWELD HEAT TREATMENT
Electrode - Flux (Class) N/A Flow Rate L/M N/A Temp. Min. : N/A Temp. Max. : N/A
E7018 Gas Cup Size N/A

PREHEAT TC-F12

Min Preheat / Interpass Temprature

20mm ≤ T is 10˚C, 38mm ≤ T ˃20 min is 50ºC
65mm ≤ T ˃ 38mm is 66 ˚C

Partial Joint Penetration (PJP)

Welding Procedure
Pass or Filler Metal Current
Process Volts Travel Speed(CPM)
weld layers Class Dia. (mm) Type & Polarity Amps
Multi Passes SMAW E 7018 2.5 DCEP 120 ~ 140 26 ~ 28 28 ~ 30

Form E-1 (Front)

Prepared by : Certified by Reviewed by : Approved by :

Salva raj Pradyumn Kumar

Welding Inspector Welding Inspector
Kirby Building Systems - Kuwait AWS Certified Inspector
 WELDING PROCEDURE SPECIFICATIONS (PQR)

Identification # : KBS - PQR - SMAW - 59 / 2009

Company Name : Kirby Building Systems-Kuwait Revision : 4 Date: 22-Jul-20 By : Pradyumn Kumar
Welding Process(es) : SMAW (Shielded Metal Arc Weld) Authorized by : Pradyumn Kumar Date : 22-Jul-20
Type - Manual X Semi - Automatic
Welding Code: AWS D1.1-2015 - Machine - Automatic

POSITION
Type : Fillet Weld (T- Joint & Corner Joint) Position of Groove N/A Fillet ALL
Vertical Progression: Up Down
Single X Double welded :
Backing : Yes No : x
Backing Material : Weld Metal ELECTRICAL CHARACTERISTICS
Root Opening R = 0-3 mm Rt Face Dim,n. 0-3 mm Transfer Mode (GMAW): N/A
Groove Angle 60⁰[+10⁰/-5⁰] Radius(J-U) N/A Short-circuiting Globular Pulsed Spray

Backgouging: Yes NO X Method : N/A Current: AC DC X

Polarity EP X EN
BASE METALS Other:
Material Spec: ASTM A 572 ASTM A 572
Type or Grade: Grade 50 Grade 50 Tungsten Electrode (GTAW):
Thickness : T1= T2 = 10mm Size N/A Type N/A
Groove / Fillet : N/A
TECHNIQUE
FILLER METALS Stringer or Weave Bead Either
AWS Specifications AWS 5.1 Multi-pass or single Pass (per side) Multi Pass
AWS Classification E7018 Number of Eectrodes Single Electrode
Manufacturer/Trade Name Supron Electrode Spacing: Longitudinal N/A
Lateral N/A Angle N/A
SHIELDING Contact Tube to Work Distance N/A
Peening / Interpass Cleaning N/A
Flux N/A Gas N/A N/A
Composition N/A POSTWELD HEAT TREATMENT
Electrode - Flux (Class) N/A Flow Rate L/M N/A Temp. Min. : N/A Temp. Max. : N/A
E7018 Gas Cup Size N/A
TC-F12
PREHEAT

Preheat Temp, Min: 20˚C

Interpass Temp, Min: 215˚C Max.

T1=T2=10mm
Partial Joint Penetration (PJP)
Welding Procedure
Pass or Filler Metal Current
Process Volts Travel Speed(CPM)
weld layers Class Dia. (mm) Type & Polarity Amps
Multi Passes SMAW E 7018 2.5 DCEP 130 27 29

Prepared by : Certified by Reviewed by : Approved by :

Pitchai Selvaraj Pradyumn Kumar

QA /QC. Manager Welding Inspector
Welding Inspector AWS Certified Inspector
Surface Preparation and Painting
Procedure
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
SURFACE PREPARTION & PAINTING EFF. DATE : 23.07.15
Page No. : 2 of 5
Quality Control Department PROCEDURE (Internal Use only)

TABLE OF CONTENTS

1.0 GENERAL

2.0 REFERENCE STANDARDS

3.0 SURFACE PREPARATION

4.0 PAINT APPLICATION

5.0 INSPECTION & TESTING

6.0 RECTIFICATION OF PAINT DAMAGE AREA

7.0 HANDLING & STORAGE

8.0 SAFETY
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
SURFACE PREPARTION & PAINTING EFF. DATE : 23.07.15
Page No. : 3 of 5
Quality Control Department PROCEDURE (Internal Use only)

1.0 GENERAL

This Work Instruction (WI) defines the minimum functional requirements related to coating works and
inspections of protective coatings for Pre Engineered steel Building components..

2.0 REFERENCE STANARDS

* Paint Manufacturer data sheet

* ISO 8504-2, ISO 8503: Preparation of steel substrates before application of paints
* American Standard Specification for surface texture, ANSI – B 46.1
* SSPC : The Society for Protective Coatings

3.0 SURFACE PREPARATION

The performance of protective coatings of paint and relative products applied to steel is significantly affected
by the state of steel surface prior to paint application. Surface preparation of components shall be carried out
by steel shots / Garnet blasting according to the recommendation of ISO 8504 – 2, and surface preparation
grade shall be as per project spec. in accordance with ISO 8501.The profile of blasted surface shall be
conformed to ISO – 8503 / ANSI – B 46.1.

The principal factors that are known to influence this performance are:

* The presence of rust and mill scale,

* The presence of surface contaminates, including salts, dust, oils / grease
* The surface profile.

Hence, prior to paint application ensure that the steel surface is free from above mentioned factors. Surface
preparation prior to paint shall be free from visible oil, grease and dirt, and from mill scale, rust, paint coatings
and foreign matter. Any remaining traces of contamination shall show only as slight strains in the form of spots
or stripes.
4.0 PAINT APPLICATION:

4.1 PRIOR TO APPLICATION ENSURE FOLLOWING SHALL BE OBSERVED

* Painting shall be done as per Paint manufacturer Data Sheet.

* Painting process shall start only when the surface temperature is 3° C above Dew point or Relative
Humidity is less than 85 % and in Presence of sand storm visibility is 25 meter or more.

* Coating / paint application shall have full coverage of specified DFT, which shall be confirmed by DFT
(Dry Film Thickness) check gage i.e. Elcometer digital gage.

4.2 PROJECT SPECIFIED PAINTS SYSTEM AS BELOW;

Standard Painting:
Surface preparation : Sa2.5
Paint System:
Primer: Interseal1052 @190µm
Top Coat: Interthane 990SG@50µm
Total: 240µm
Painting shall be applicable as per the contract requirement.
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
SURFACE PREPARTION & PAINTING EFF. DATE : 23.07.15
Page No. : 4 of 5
Quality Control Department PROCEDURE (Internal Use only)

4.3 PAINTER MUST MAINTAIN A REGISTER / LOG BOOKSHOWING FOLLOWING

INFORMATION:

* Supplier's name and paint Batch #

* Job # and piece mark,
* Ambient temperature and relative humidity,
* Quantity of steel members painted with that batch #
* Date and time of application.
NOTE: Packing and shipment of the steel members shall be done when the paint is fully cured.
4.4 Coatings that have gelled and exceeded their pot life shall be discarded.
4.5 The equipment, Air pressure, Tip sizes, Hose size etc shall be as per the paint manufacturer's product
data sheet.
4.6 Welds, edges, bolts, rivets shall be given a brush applied stripe coat before applying the full coat
whenever possible. All full coats shall be applied by airless spray, unless otherwise instructed.
4.7 Re-coating intervals, mist coat if required and drying times shall be in accordance with the material
manufacturer’s published instructions.
4.8 Wet Film Thickness (WFT) shall be measured to ensure the required Dry Film Thickness (DFT) by
Painters.
4.9 The DFT shall be as per the job requirement and shall be measured & recorded.
4.10 Re-coating intervals, mist coat if required and drying times shall be in accordance with the material
manufacturer’s published instructions.
4.11 Wet Film Thickness (WFT) shall be measured to ensure the required Dry Film Thickness (DFT) by
Painters.
4.12 The DFT shall be as per the job requirement and shall be measured

5.0 INSPECTION & TESTING

Before the beginning of the works a pre-job meeting shall be arranged between paint supplier and plant
painting foremen, Operators and QC inspectors to clarify and agree the production procedures, checks and
inspections program, report forms and any other necessary requirements to achieve the correct job execution.

5.1 Preliminary checks / Tests: Upon arrival of paints, the warehouse receiver and QC inspector shall verify;

* Verify with the correspondence P.O., shipping documents and Identification of the containers,
* The containers integrity;
* The validity of shelf life of paint
* All the incoming Blasting / Coating consumables like Steel shots, Grits, Paints, Thinner and Cleaner etc.
shall be checked by QC to verify the P.O. requirements and Test Certificate.
5.2 The prepared surface shall be inspected. The degree of cleanliness shall be per project requirement (e.g.
SA2.5).
5.3 Profile (anchor pattern) prior to coating shall be measured and recorded.
5.4 Visual standard for abrasive blast cleaning steel, SSPC VIS 1 shall be used as a guide for inspecting the
degree of cleanliness.
5.5 Surface profile gages, Keane-Tator surface profile comparator, Testex press-o-film, Replica Tape shall
be used to determine surface profile of blast cleaned surfaces.
5.6 In-process inspection is carried out to ensure that the correct coating material, mixing, application etc. is
as per the manufacturer product data sheet and project specification.
5.7 DFT of each coat shall be measured in accordance with SSPC-PA2 or ASTM D 7091 using an
Elcometer-456 digital coating thickness gage or its equivalent.
5.8 All the weather conditions such as Relative humidity, Substrate temperature, Dew Point etc. shall be
recorded for minimum 4 hours interval (depends on the weather condition).
5.9 The Inspector shall ensure that the blasting, coating procedure is followed properly.
5.10 All the measuring instruments used for blasting & painting shall be calibrated.
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
SURFACE PREPARTION & PAINTING EFF. DATE : 23.07.15
Page No. : 5 of 5
Quality Control Department PROCEDURE (Internal Use only)

6.0 RECTIFICATION OF PAINT DAMAGE AREA.:

This Rectification Procedure applicable on area due to mud cracks observed on edges and corners due to
high DFT’s and due to mechanical damages in transit damage.

6.1 Surface Preparation Requirements:

6.1.1 Identify and mark the paint damage (crack) areas, cleanliness shall be made by hand tool, power tool
or blast cleaning as per the suitability of site.
6.1.2 Remove oil and grease etc. thoroughly with suitable thinner/detergent. Remove salts and other
contaminants by high pressure freshwater cleaning.
6.1.3 The damaged areas shall be rectified as per SSPC PA1.
6.1.4 Surface profile shall be as stated in the paint manufacturer’s published recommendations.

6.2 Painting:

6.2.1 All damaged areas and field weld connection areas of shop coated surfaces shall be repaired with
same coating system used in the initial coating (or) its equivalent. Substitution of an organic Zinc
primer for inorganic Zinc is permitted for field repairs. No substitution of topcoats is permitted.
6.2.2 Clean the presence of surface contaminates, including salts, dust, oils / grease from the surface.
Scrape off loss paints by sharp knife. Roughen the affected areas.
6.2.3 Application paint touch up shall be by airless spray (or) brush /roller.
6.2.4 Re-coating intervals, drying times shall be in accordance with the material manufacturer’s published
instructions.

7.0 Site Handling & Storage:

7.1 Adequate packaging is to be ensured that the product is protected from contamination.
7.2 Painted material shall be handled by nylon belts, forklift mark should be avoided.
7.3 Since lower temperature during winter minimize the useful life, all paints to be stored covered and in
warm surrounding.
7.4 Storage area should be isolated and well protected from heat and fire.
7.5 Any paint damage in handling & storage shall be made ASAP & as per clause 6.0.
7.6 If Primer coat is final coat for the painted material, it is strongly recommended to apply a complete paint
system (suggested by paint manufacturer) within 2months from receipt of material at site in order to
protect the steel from rust/corrosion.

8.0 Safety:

8.1 Any surface preparation, painting or rectification shall be made under Kirby safety regulations. Safety in-
charge shall impart the rules and regulation & shall be randomly monitored the activities. Rectification
crews shall also follow the respective country’s Safety regulations.

Blasting & Painting Inspection Report Format: