S15 - Structural Steelwork

EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH.
, C&S AND MEP
SECTION 15 : STRUCTURAL STEELWORK
TABLE OF CONTENTS
CONTENTS PAGE
15.1 General ................................................................................... S15-11 Field Code Changed
15.1.1 Extent of Work .............................................................. S15-11

15.1.2 Standards ..................................................................... S15-11
15.1.3 Testing and Inspection .................................................. S15-11
15.1.4 Materials ....................................................................... S15-22
15.1.5 Galvanised Work .......................................................... S15-22
15.1.6 Working Drawings ......................................................... S15-77
15.1.7 Fabrication .................................................................... S15-77
15.1.8 Holes .........................................................................S15-1616
15.1.9 Transportation to Site.................................................S15-1616
15.1.10 Erection .....................................................................S15-1717
15.1.11 Steel Flooring.............................................................S15-1717
15.2 Setting and Grouting Baseplates ..................................................S15-1818
15.3 Holding Down Bolts......................................................................S15-1919
15.4 Painting Structural Steelwork (not galvanised) ............................S15-1919
15.5 High Strength Friction Grip Bolts .................................................S15-2525
i
Revised on 6 Oct. 2011
EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH., C&S AND MEP
SECTION 15 – STRUCTURAL STEELWORK
15.1 General
15.1.1 Extent of Work
The work covered by this section of the Specification consists of

furnishing all plants, labour, equipment, supervision, appliances and
materials, and of performing all operations in connection with the
fabrication and erection of Structural and Miscellaneous Iron and Steel
work together with all anchors, fastenings, hardware, accessories and
other supplementary parts necessary to complete the work in strict
accordance with this section of the Specification and the applicable
drawings and subject to the terms and conditions of the Contract.
15.1.2 Standards
This Specification shall be read in conjunction with the standards in the

Appendix which are deemed to form part of this Specification. In the event of
contradiction between this Specification and standards, the requirements of
this Specification shall take precedence. Reference to any standard shall
include any amendment thereto.
15.1.3 Testing and Inspection
Whenever required, the Contractor shall satisfy the S.O. by means of Formatted: Not Highlight
numbers or identification marks on the steel, combined with a

manufacturer's certificate that such steel has been tested and complies with
all tests and requirements of the relevant British Standards.
Notwithstanding the conditions above, the S.O. may direct from time to time Formatted: Not Highlight
as the work proceeds that the whole or part of the steel used in the Works
shall be subject to inspection and tests.
In case there is a reasonable doubt in the first trial as to the ability of this
steel to meet any requirement of this specification, two additional tests shall
S15-1
be made on samples of steel from the same batch, and if failure occurs in
either of these tests, the steel shall be rejected. The steel shall be rejected
immediately if any sample fails to attain 95% of the characteristic strength.
15.1.4 Materials
All materials used in the permanent works shall be of first class quality
obtained from an approved manufacturer and shall in all respects comply
with the relevant British Standards.
All ironwork, both cast and wrought, shall be free from all defects. All
castings shall be perfectly true, clean and sharp and be free from air blows
and sand pockets.
High tensile structural steel shall be Grade 50B to B.S. 4360 having
minimum yield stress of 355N/mm2.
Mild structural steel shall be Grade 43A to B.S. 4360 having minimum yield
stress of 245N/mm2.
High strength Friction Grip Bolts shall be of general grade in accordance

with B.S. 3139 Part 1.
Mild steel Black Bolts shall comply with B.S. 916.
Electrodes used in welding shall comply with B.S. 639:1986.
Stainless steel shall comply with the requirements of B.S. 970: Part 1 - 1983
and the quality shall be SS 316.
15.1.5 Galvanised Work
15.1.5.1 General
All galvanizing works where specified shall be hot-dip galvanized and shall
conform to the requirements of B.S. 729: 1971.
S15-2
Hot-dip galvanizing is defined as a coating of zinc and zinc- iron alloy layers,
obtained by dipping prepared iron or steel articles in molten zinc. Under
some circumstances the whole coating may consist of zinc-iron alloy layers.
15.1.5.2 Fabrication
Care shall be taken to avoid fabrication methods which could cause

distortions or embrittlement of the iron and steel articles.
Unsuitable marking paints, grease, oil and other deleterious materials shall
be removed prior to fabrication of steel and iron articles.
Holes and/or lifting lugs to facilitate handling, venting and draining during the
galvanizing process shall be provided at approved positions.
15.1.5.3 Surface Preparation
Materials to be galvanized shall be thoroughly cleaned of all scale, dust and

dirt by pickling in a bath of muriative acid.
All welding slags and burrs, surface contaminants and coatings which
cannot be removed by the normal chemical cleaning process in the
galvanizing operation shall be removed by wire brush or other suitable
methods approved by the S.O.. Formatted: Not Highlight
15.1.5.4 Galvanizing
Materials to be galvanized shall be handled with care so as to avoid any

mechanical damage and to minimize distortion.
The materials shall be dipped in a galvanizing bath of molten zinc containing

not less than 98.5% zinc at suitable galvanizing temperature and shall
remain in the bath until all surfaces are evenly coated with firmly adherent
spelter and the coating requirements shall comply with Clause 15.1.5.5 of
this specification.
S15-3
15.1.5.5 Coating Requirements
(a) Coating Weights and Thickness
The weight and thickness of the galvanizing coating shall comply

with the minimum values as shown in Table 15.1.
Table 15.1: Coating Weights
Minimum Average Coating on

Material any Individual Test Area
Coating Equivalent
Weight Thickness
g/m2 um
Steel 5 mm thick and over 610 85
Steel under 5 mm thick but
not less than 2 mm 460 64
Steel less than 2 mm thick but
not less than 1 mm 335 47
Steel articles which are
centrifuged 305 42
Grey and malleable iron
casting 610 85
The weight for galvanized coatings for threaded works/ fasteners

shall not be less than 375g/m2 or the equivalent thickness of the
coatings shall not be less than 52 microns.
(b) Surface Finish
The galvanized coating shall be continuous, adherent, as smooth

and evenly distributed as possible, and free from any defect or
imperfections that is detrimental to the usage of the coated article.
Where slip factors are required to enable high strength friction grip
bolting, where shown, these shall be obtained after galvanizing by
suitable mechanical treatment of the faying surfaces.
Where a protective coating is to be applied the galvanized materials,

all spikes shall be removed and all edges shall be free from lumps
and runs.
S15-4
(c) Adhesion
The galvanized coating shall be sufficiently adherent to withstand

normal handling during transport and erection without peeling or
flaking and light blows with a 0.3kg hammer shall not cause the
coating to peel adjacent to the area deformed by hammer blows.
15.1.5.6 Inspection
The integrity of the galvanized coating shall be determined by visual

inspection and coating thickness measurement. The thickness of the
galvanized coating can be measured by using an approved magnetic or
electronic measuring device or other methods approved by the S.O.. Formatted: Not Highlight
Any galvanizing shown to be defective on inspection or by the hammer-blow

tests will be rejected. Any work so rejected shall be rectified by the
Contractor at his own expense.
15.1.5.7 Transport and Storage
Galvanized articles, shall, wherever possible, be transported and stored

under dry, well-ventilated conditions to avoid the possibility of wet storage
staining.
Where required, post-treatment of galvanized products such as chromating

or phosphating may be applied to reduce the risk of wet storage staining or
to assist subsequent painting.
15.1.5.8 Welding
Where galvanized steel is to be welded, adequate ventilation shall be

provided. If adequate ventilation is not available, supplementary air
circulation shall be provided. In confined spaces a respirator shall be used.
Grinding of edges prior to welding may be permitted to reduce zinc oxide

fumes formed during welding and eliminate weld porosity which may occur.
S15-5
All uncoated weld areas shall be reinstated as per the Coating

Reinstatement of Clause 15.1.5.9 of this Specification. Formatted: Not Highlight
15.1.5.9 Coating Reinstatement
Small areas that are uncoated and/or small areas of galvanised coating
damaged by welding, cutting or by excessively rough treatment during
transit and erection may be reinstated either by the use of low melting point
zinc alloy repair rods or powders made specifically for this purpose, or by the
use of at least two coats of good quality zinc-rich paint. Sufficient material
should be applied to provide a zinc coating at least equal in thickness of the
galvanised layer.
15.1.5.10 Painting for Galvanised Sundry Steelworks and Galvanised Iron

Gutters
Unless otherwise specified all galvanised sundry steelwork and galvanised

iron gutters shall be painted with approved paint manufacturer strictly in
accordance with the following:-
(a) Galvanised Sundry Steelworks
1 coat of Etch Primer applied to the steel surfaces at a rate of 20

square metres per litre of solution and thoroughly washes down Formatted: Not Highlight
with clean water after application.
1 coat of Micaceous Iron Oxide Epoxy to a dried film thickness of

150 microns.
1 cost of Aliphatic Recoatable Two Pack Polyurethane each coat

to a dried film thickness of 50 microns.
(b) Galvanised Iron Gutter and Grating
i. Surface exposed to weather but not exposed to view
S15-6
1 coat of Etch Primer applied to the steel surfaces at a rate of

20 square metres per litre of solution and thoroughly washes Formatted: Not Highlight
down with clean water after application.
1 coat of Micaceous Iron Oxide Epoxy to a dried film

thickness of 150 microns.
1 coat of High Built Solid Tar Epoxy to a dried film thickness

of 125 microns.
ii. Surface not exposed to weather
Coating system similar to Clause 15.1.5.10 (a) above.
(c) Galvanised Iron Downpipes
Coating system similar to Clause 15.1.5.10(a) above.
15.1.6 Working Drawings
Two copies of all detailed working drawings prepared by or on behalf of the

Contractor at his own expense shall be submitted to the S.O. for his Formatted: Not Highlight
approval, but this approval shall in no way relieve the Contractor of his
responsibilities for the work under the Contract.
15.1.7 Fabrication
15.1.7.1 General
(The Works shall be carried in accordance with B.S. 5950).
(a) Inspection, etc.
All workmanship shall be of first class quality in every respect, the

greatest accuracy being observed to ensure that all parts will fit
together properly on erection.
S15-7
The S.O. shall have full liberty at all reasonable times to enter the Formatted: Not Highlight
premises of the Contractor for the purpose of inspecting work, and

no work shall be taken down or packed until it has been inspected
and approved. Any work found defective or which is not in
accordance with the drawings or this specification shall be rejected
and, if so, shall at once be made good. The Contractor shall supply
free of charge all labour, tools, scaffolding, etc. required in
connection with the inspection of the Works.
(b) Templates, measurements, etc.
All templates, jigs and other appliances necessary to ensure the

accuracy of the work shall be provided by the Contractor.
All measurements shall be made by means of an approved steel

tape.
(c) Straightening
Before any other work is done on them, all plates shall be checked
for flatness and all bars and sections checked for straightness and
freedom from twist and any corrective action shall be taken so that,
when assembled, adjacent surfaces shall be in close contact
throughout. The methods adopted for the above work shall be such
as not to injure or mark the material.
(d) Unless otherwise specified, steelwork may be cut by shearing,

sawing or flame cutting. Surfaces produced by such cutting shall be
finished square (unless a bevelled edge is called for), true and
smooth to the required dimensions. Finishing of surfaces shall
generally be by machining and/or grinding. In the case of flame
cutting, surfaces having only slight irregularities may be lightly
ground, provided that the finished edges are substantially as straight,
true, smooth and regular as those produced by the finishing cut of a
planning machine. Formatted: Not Highlight
S15-8
Shearing will not be permitted for main plates, reinforcing plates,

main gussets and splice plates except in a direction perpendicular to
the direction of their main stresses.
Edges of flange plates or built-up I-sections and plate girders and

edges of splice plates and plates of other built-up sections in the
direction of their main stresses shall be machined or flame cut.
Ends of stiffeners shall be cut and finished to fit tightly to the girder
flanges.
The butting ends of compression flanges and compression

members, and of girders and other members which are to be spliced
by riveted or bolted joints, shall be faced after fabrication so as to be
in close contact throughout.
15.1.7.2 Welding, Supervision of Welding Flame Cutting Procedure Trials
(a) When directed by the S.O. and before fabrication is commenced, Formatted: Not Highlight
welding and flame cutting procedure trials shall be carried out using
representative samples of materials to be used in the Works.
The samples of materials shall be selected and marked by the S.O. Formatted: Not Highlight
when the materials for the work are inspected at the mills.
Trials on material 20mm thick shall be taken to include all material

up to but not exceeding 20mm thick. Trials on material 40mm thick
shall be taken to include material over 20mm and up to but not
exceeding 40mm thick. Materials over 40mm thick shall be tested for
every thickness increment of 6mm.
The welding and flame cutting trials shall demonstrate to the

satisfaction of the S.O. the procedures to be adopted in the Formatted: Not Highlight
fabrication of the work which shall include:
i. Welding procedure in accordance with B.S. 5135:1974.
S15-9
ii. The heat control techniques required to ensure that the

flame cut surfaces of steel are free from cracks, local
hardness, and any other defects which would be
detrimental to the finished work.
The trials shall include specimen weld details representative of the

actual construction which shall be welded in a manner simulating the
most unfavourable conditions liable to occur in the particular
fabrication. Where primers are to be applied to the work prior to
fabrication, they shall be applied to the sample material before the
procedure trials are made. After welding the specimens shall be held
at a temperature not less than 50 degree Fahrenheit for a period not
less than 72 hours and shall then be sectioned and examined for
cracks and other defects.
(b) The following groups of tests to B.S. 709: 1971 shall be carried out in
accordance with Clause 15.1.7.6.
i. Butts Welds :
Transverse tensile test.
Transverse and longitudinal bend tests.
Separate tests shall be performed in each case with the root

of the weld in tension and compression respectively.
Charpy V-notch impact tests except for Grades 43A and 50B
steels to B.S. 4360: 1972.
Macro examination test. Formatted: Not Highlight
ii. Fillet Welds :
Fillet weld fracture test.
Macro examination test.
S15-10
15.1.7.3 Qualification and Testing of Welders
Only skilled welders shall be employed and shall have previously

undertaken selected tests as described in B.S. 4871.
15.1.7.4 Supervision of Welding
Welding shall be carried out only under the direction of an experienced and
competent supervisor. Unless otherwise agreed by the S.O., a record shall Formatted: Not Highlight
be kept to enable major butt welds to be identified with the welders

responsible for the work but finished work shall not be marked by hard
stamping for this purpose.
15.1.7.5 Welding Plant
The welding plant shall be capable of maintaining at the weld the voltage
and current specified by the manufacturer of the electrodes. The Contractor
shall supply instruments for verifying voltages and current as and when
required by the S.O.. Formatted: Not Highlight
15.1.7.6 Welding
Unless otherwise described in the Contract, metal-arc welding shall comply

with B.S. 5135: 1974 as appropriate except for tack welds and temporary
attachments for which the procedures laid down in B.S. 5135: 1974 shall be Formatted: Not Highlight
followed. Formatted: Not Highlight
The temperature of steels welded in accordance with B.S. 5135: 1974 shall
not be less than 50 degree Fahrenheit when welding is commenced.
Electrodes and fluxes shall be used in accordance with the manufacturer's

instructions. The use of welding processes other than those covered by B.S.
5135: 1974 shall be subject to the approval of the S.O.. Formatted: Not Highlight
The general welding programme for shop and site weld, including particulars
of the preparation of fusion faces, the method of pre-heating and/or
post-heating where approved by the S.O., the methods of making the welds, Formatted: Not Highlight
S15-11
the number of passes proposed for particular welds and the types of
electrodes shall be submitted to the S.O. for his approval before the work is Formatted: Not Highlight
put in hand. No departure from the agreed welding programme or from the
details shown on the Drawings shall be made without the agreement of the
S.O.. Electrodes and fluxes shall be so chosen that the properties of the Formatted: Not Highlight
deposited metal are not inferior to those of the parent metal. Particular care
over choice of welding technique shall be taken to minimise residual weld
stresses and deformation of the steel due to welding.
The procedures for welding and flame cutting established by the procedure
trials under Clause 15.1.7.2 shall be strictly followed.
Unless otherwise described in the Contract, all butt welds shall be complete
penetration welds made between prepared fusion faces.
In the fabrication of built-up assemblies, all butt welds in each component

part shall be completed, whenever possible, before the final assembly.
The position of welds required for temporary attachments shall be agreed by

the S.O. before the work commences. Formatted: Not Highlight
Where automatic or semi-automatic processes are used, back gouging of

the deposited weld will not be required where the S.O. is satisfied that the Formatted: Not Highlight
root run is free from imperfection.
Where butt welds are to be ground flush there shall be no loss of parent
metal. The final grinding shall be in the direction described in the Contract.
Stud shear connectors shall be welded in accordance with the

manufacturer's instructions.
In butt joints the root edges or root faces shall not be out of alignment by
more than one eighth of the thickness of the thinner material for material up
to 12mm thick or by more than 1.5mm for thicker material.
Requirements for 'run-on' plates and 'run-off' plates shall be as follows:-
S15-12
(a) One pair of run-on plates and one pair of run-off plates all prepared
to the same thickness and profile as the parent metal shall be
attached by clamps to the start and finish respectively of all butt
welds. Unless otherwise required by the S.O., approximately 1 in 5 Formatted: Not Highlight
pairs of run-off plates for butt welds in tension flanges and 1 in 10

pairs for other butt welds shall be production test plates. The
combined size of each pair of production test plates shall be either
230mm, 300mm or 380mm wide x 200mm long, as shown in Table
15.2, the length being measured in the rolling direction of the metal
and at right angles to the weld.
Table 15.2: Sizes of run-off Production Test Plates
Combined Size (per pair) of

Run-off Production Test Plates
Plates Up Plates from Plate Over to
30 mm Thick 30 mm to 75 mm Thick
75 mm Thick
Steel of Grades Sizes to be
43A and 50B to 230 x 200 300 x 200 agreed with the
B.S. 4360 : 1972 S.O. Formatted: Not Highlight
Steel of Grades
40C, D and E,
43C, D, and E 300 x 200 380 x 200
and 50C to
B.S. 4360 : 1972
(b) Butt welds shall run the full length of the joint and extend at full weld
profile for a minimum distance of 200mm x 275mm and 250mm
respectively into the 230mm x 300mm, 300mm x 200mm and
380mm x 200mm run-off production test plates.
(c) On completion of the welds the run-off production test plates shall
not be removed until they have been marked in a manner agreed by
the S.O. to identify them with the joints to which they are attached. Formatted: Not Highlight
S15-13
(d) When removing the run-on and run-off plates by flame cutting, the
cuts shall not be nearer than 6mm to the sides of the parent metal
and the remaining metal shall be removed by grinding or other
method agreed by the S.O.. Formatted: Not Highlight
(e) Specimens for the following tests to be carried out in accordance

with Clause 15.1.7.7 shall be selected from the run-off production
test plates by the S.O.: Formatted: Not Highlight
i. Transverse tensile test(s). (The number of test piece shall be

sufficient to cover the full thickness of plate).
ii. Transverse bend test.
iii. Three Charpy V-notch tests except for steel of Grades 43A
and 50B to B.S. 4360: 1972.
15.1.7.7 Testing of Welding
The tests detailed in Clause 15.1.7.2 and 15.1.7.6 shall be carried out by the
methods described in B.S. 709: 1971. The following requirements shall also
be met:-
(a) The test results of welded joints shall not be inferior in any respect to
the British Standard test requirements for the parent metal.
(b) Procedure Trials (Clause 15.1.7.2)
i. Tensile and Bend Tests: Should any one of the weld joint
test pieces selected for transverse tensile and transverse
and longitudinal bend tests fail to comply with the test
requirements applicable to the parent metal of the joint
represented by the test, 2 additional test pieces shall be
taken from the joint material represented by the test. Both
shall then comply with the test requirements in order to
qualify for acceptance.
S15-14
ii. Charpy V-notch Tests: Should the average impact value

obtained from any set of 3 Charpy V-notch specimens fail to
comply with the test requirements, 3 additional test pieces
from the same sample shall be tested. The average of the 6
test results shall comply with the test requirements in order to
qualify for acceptance.
iii. Revised Procedures: In the event of failure to meet the test

requirements, the Contractor shall carry out further trials
using revised procedures and further tests to the satisfaction
of the S.O.. Formatted: Not Highlight
(c) Procedure Test (Clause 15.1.7.6)
i. Production Test Plates: The run-off production test plate

sizes specified shall be cut on the instructions of the S.O. in Formatted: Not Highlight
order to enable up to 2 complete sets of test specimens to be

obtained.
ii. Tensile and Bend Tests: Should any one of the weld joint
test pieces selected for transverse tensile and transverse
bend tests fail to comply with the test requirements
applicable to the parent metal of the joint represented by the
test, additional specimens shall be cut from the same
production test plates and the tests repeated. Should either
of the additional tests fail to comply with the requirements,
the joint shall be rejected.
iii. Charpy V-notch Tests: Should the average impact value

obtained from any set of 3 Charpy V-notch specimens
selected fail to comply with the test requirements, 3
additional test pieces from the same production test plates
shall be tested.
Should the average of the 6 test results fail to comply with

the test requirements, the joint shall be rejected.
S15-15
iv. Re-welding and Re-testing: In the event of failure to meet the

test requirements the welded joint represented by the tests
shall be completely cut out. The joint shall then be rewelded
and the tests repeated.
(d) Non-destructive Testing
A method of non-destructive testing agreed with the S.O. shall be Formatted: Not Highlight
used for the examination of butt welds in tension members and

where otherwise directed by the S.O.. Formatted: Not Highlight
(e) Radiographic Inspection of Welding
As a further control of weld quality, the Contractor will be requested

to submit for approval radiographs of weld selected by a competent
inspector to be approved by the S.O.. The length of weld to be Formatted: Not Highlight
radiographed at any one location shall be determined by the S.O.. Formatted: Not Highlight
Where radiographic inspection reveals defects in the welds, the

welds shall be re-welded or the Contractor shall be permitted to carry
out repairs and these shall be required to pass the radiographic
inspection at the Contractor's expense.
15.1.8 Holes
All holes shall be accurately marked off from templates or corresponding

plates, and drilled, except in plates 10mm thick or under, when they may be
punched. Holes should be cleaned or burrs or rough edges and
counter-sunk where required. No drifting shall be allowed. The diameter of
holes should not exceed the diameter of the bolt or rivet by more than 2mm.
15.1.9 Transportation to Site
Long members are to be bundled for transport. No "projecting" members are

to be left on long members which can cause bending or damage of these
S15-16
during transit. Cleats and small parts are to be bagged and packed in kegs
or cases.
15.1.10 Erection
Erection procedure shall be in accordance with proposals submitted by the

Contractor and approved by the S.O., and no divergence from the approved Formatted: Not Highlight
procedure will be permitted except if agreed to in writing by the S.O.. Formatted: Not Highlight
The Contractor shall inform the S.O. when fabricated sections are ready for Formatted: Not Highlight
inspection prior to erection. No erection shall then be permitted until the S.O. Formatted: Not Highlight
approves the fabrication.
During erection care shall be taken to avoid any shock, dynamic or

vibrationary loading of the members.
No members in the Works shall be finally bolted, welded or otherwise joined

until the whole of a major section is approved by the S.O.. Connection shall Formatted: Not Highlight
be made as soon as possible after the S.O.'s written approval is received. Formatted: Not Highlight
Care shall be exercised to avoid interference with members already in place.
15.1.11 Steel Flooring
(a) Chequered Plate Floor
Unless otherwise specified steel flooring shall be of mild steel 10mm

thick chequered plate (minimum thickness).
The steel flooring shall be installed with all chequered plates fully
welded together and fixed on to supporting members with diameter
10mm counters and bolts at 450mm c.c. at the perimeter of the
welded plates and edges of openings (if any).
Holes of the correct diameter and spacing shall be drilled in the plate
and steel supporting members during installation at site. No tack
S15-17
welding is allowed for fixing the chequered plate to the steel

supporting members unless otherwise approved.
Unless otherwise stated all underside of M.S. chequered plate

flooring shall be painted as specified in Clause 18.4 of this Section.
Chequered plate treads for staircase need be painted as well.
(b) Gridmesh Floor
Gridmesh steel flooring shall be of hot-dipped galvanized steel

expended metal gridmesh, manufactured by 'John Lysaght' Code
No. XPM Gridmesh No. GM50105 cut to required size and shape to
suit the floor area.
The steel flooring shall be installed with all expanded metal gridmesh
joined together and fixed on to the supporting members by welding
and touch up with approved paint and in compliance to the
Manufacturer's recommendations.
Areas of galvanized coating of gridmesh which are damaged shall

be reinstated as per Clause 15.1.5.9.
15.2 Setting and Grouting Baseplates
Unless otherwise specified in the drawing, box-outs/pockets are to be filled

with `Masterflow 870A' non-shrink cementitious grout in accordance to
manufacturer's recommendations and to be rammed in tight into the pockets
and under the base plate and around the levelling plates. Adequate levelling
and seating plates shall be provided and placed to required level on
approved high strength mortar before the baseplates can be installed in
position.
All steelwork shall be completely erected, all bolts fully tightened and all
stanchions fixed and grouted up before any cladding is placed or fixed.
S15-18
15.3 Holding Down Bolts
The Contractor shall supply and position holding down bolts as detailed in
the drawings including nuts, washers m.s. angles, etc. They shall be fixed
accurately and rigidly to the lines and levels as shown in the drawings. It is
absolutely necessary to ensure that the bolts are not disturbed once
positioned and care shall be taken to ensure that the bolts are not displaced
during concreting.
15.4 Painting Structural Steelwork (not galvanised)
15.4.1 Surface Preparation
(a) With Power Wire Brushing
Non-adherent millscale shall be removed by hand chipping or

S.O.hanical cleaning with power operated tools. The surfaces shall Formatted: Not Highlight
then be power wire brushed to remove tightly adhering rust and all
disintegrated millscale. The surface shall be thoroughly dry and
degreased before application of paint.
(b) With Shot Blasting
Blast cleaning shall be carried out generally as specified in B.S.

4232 and in an enclosed air-tight well lighted chamber to prevent
the escape of dust and causing dust contamination to the
surrounding areas and to steel surfaces to be coated.
The surfaces to be prepared for coating shall first be cleaned by

removal of all loose scale and surface deposits, spelter, weld slag
and splatter by chipping and brushing. Paint, oil, grease and similar
contamination shall be removed by washing and the use of solvents
if necessary.
S15-19
Steel surfaces shall be blast cleaned to Second Quality Finish; Near

White Metal; B.S. 4232. This is equivalent to Swedish Standard SA.
2.5.
The Surface Finish is defined as one from which all oil, grease, dirt,
mill scale, rust, corrosive products, oxides, paint or other foreign
matter have been completely removed from the surface except for
rust stain, mill scale oxides or slight, tight residues of paint or coating
that may remain. At least 95% of surface area shall be free of all
visible residues, and the remainder shall be limited to the light
discoloration mentioned above.
The abrasive used shall be dry and free from contamination and all
material shall be cleaned and sieved to the satisfaction of the S.O. Formatted: Not Highlight
before re-use. The use of silica sand or mineral grits containing silica
will not be permitted.
The compressed air supply used for blasting shall be free of water
and oil. Adequate separators and traps shall be provided and these
shall be kept emptied of water and oil. Operating pressure at blast
nozzle shall be a minimum of 0.7N/mm2.
All welded areas and appurtenances shall be given special attention

for removal of welding flux in crevices. Welding splatter, slivers,
laminations, and underlying mill scale exposed during blasting shall
be removed or repaired. Bolt holes shall be drilled and smoothened
prior to blasting ensuring all burrs are removed.
No acid washers or other cleaning solutions or solvents may be used

on metal surfaces after being blasted. This includes any inhibitive Formatted: Not Highlight
washes intended to prevent rusting.
Blasted surface shall not be touched or otherwise contaminated and

shall be coated or otherwise protected before deterioration takes
place. When and where deterioration has occurred, sweep-blasting
shall be carried out immediately prior to application of the protective
S15-20
coating. Prime coating should not, even under favourable conditions,

be carried out more than 4 hours after blasting.
15.4.2 Coating
Coating system for structural steelwork unless otherwise specified, shall be

carried out in strict accordance with the following:-
(a) Without Shot Blasting (For Structural Steelworks)
2 coats of High Build Zinc Phosphate Primer each coat to a dried film
1 coat of Alkyd Micaceous Iron Oxide to a dried film thickness of 50

microns.
1 finish coat of Micaceous Iron Oxide to a dried film thickness of 50

microns.
(b) Without Shot Blasting (For Handrailings, Column Protective Barrier)
2 coats of High Build Zinc Phosphate Primer each coat to a dried film
1 coat of Alkyd Micaceous iron Oxide to a dried film thickness of 50

microns.
1 finish coat of Gloss Finish - (Yellow) Each coat to a dried film

All coatings shall be obtained from the same source to ensure

compatibility. They shall be supplied in 4, 5, 20 or 25-litre capacity
and used in strict rotation. Coatings shall be stored in a lock-up store
where they are not exposed to extreme temperatures. Any special
storage conditions and precautions advised by the manufacturer
shall be closely observed.
S15-21
Use of coatings after expiration of pot-life shall not be permitted.

Coatings which have not been used within shelf life period specified
on the containers or within 12 months of the date of manufacturer
which ever is the lesser, shall be replaced. The containers delivered
to worksite shall be original.
The final coat shall be applied to the steelwork after erection.
(c) With Shot Blasting
i. The coatings for the specified paint systems mentioned

hereunder shall be manufactured by approved manufacturer.
ii. The coating system shall be as follow:-
Minimum Dried
Coating Layer Generic Type Film Thickness Colour
Microns
1st Primer Zinc Epoxy 50 Grey
2nd. Micaceous Iron 150 Dark

Intermediate Oxide Epoxy
3rd. Finish Aliphatic Recotable 50 To be

Two Pack decided by
Polyurethane Employer
iii. All mild steel chequered plates for treads and landing
platforms of external staircases.
iv. All bolts, nuts and washers for external structural steelwork
exposed to weather shall be hot dipped galvanised finish and
painted with one coat of Micaceous Iron Oxide Epoxy to a
dried film thickness of 150 microns and one coat of Aliphatic
Recotable Two Pack Polyurethane to a dried film thickness
of 50 microns. Colour to match painting for structural
steelwork.
S15-22
15.4.3 Application of Paint
(a) General Requirements
The Contractor must ensure that the paint is thoroughly mixed so

that all the pigment is in suspension and the paint is of suitable
consistency before the material is used. No oil or thinners shall be
added.
Paint shall be applied only to surfaces that are thoroughly dry and
free from grease and oil and shall be applied immediately after
surface preparation of the steel.
(b) Application of Paint
The paint shall be applied by brush or spraying.
As far as is practicable, the painted steelwork shall not be handled or

stacked until the paint is "thorough-dry" and sufficiently hard to avoid
being damaged.
Paint shall not be applied when :-
- the relative humidity rises above 90 per cent, or during rain, fog
or mist;
- condensation has occurred or is likely to occur on the steel.
Unless otherwise agreed by the S.O., each coat of paint shall be Formatted: Not Highlight
applied to produce a continuous film of paint of uniform and even

thickness. As soon as the first priming coat has dried an extra strip
coat of paint shall be applied by brush to edges, corners, crevices,
bolts heads, rivet heads and welds, using paint of a similar
composition to the heads and welds, using paint of a similar
composition to the priming coat but in contrasting shade. Successive
coats shall have different shades for identification and each coat
shall be thoroughly dry before the application of a further coat.
S15-23
The total dry paint film thickness of the paint system on bare steel
surface and on metal coated surfaces shall not be less than the
thickness specified. The Contractor shall make available at his own
cost at least one number Elcometer at each site or other approved
paint - measuring instruments to the S.O. to measure dry film Formatted: Not Highlight
thickness.
In order to obtain the dry film thickness specified, the Contractor

shall ensure that the coverage rate given by the paint manufacturer
will enable this thickness to be attained.
Wet film thickness gauges may be used for checking but shall not be
permitted as a means of predicting the dry film thickness.
The paint system, including the finishing coat, shall be applied under
cover in controlled conditions at the fabricator's shop. After erection
on the site the damaged paint surfaces shall be made good by
repainting and touching up.
No paint shall be used after expiration of the 'potlife' stipulated by the

manufacturer, and paints of limited 'potlife' shall not be mixed with
fresh paint or have thinners added to them.
No paints shall be applied to contact surfaces using H.S.F.G. bolts

unless otherwise approved or to steel members encased in
concrete.
(c) Treatment of Contact Surfaces
For assemblies which have to be fabricated by riveting, bolting or Formatted: Not Highlight
other mechanical methods, the contact surfaces must be thoroughly

cleaned and painted immediately before assembly and jointing.
Where H.S.F.G. bolts are used the contact and unpainted surfaces
should be wire brushed, free of oil, grease etc. Painting shall only be
applied after assembly and jointing.
S15-24
(d) Repair to Damaged Surfaces
Areas of paint which have been damaged during handling, storing,

loading and off-loading, transportation, erection and construction
shall be cleaned to bare metal, or metal coating where this has been
applied, and the edges of the undamaged paint bevelled with
sandpaper.
Where a metal coating has been damaged, the affected area shall
be rubbed down to remove excessive roughness, cleaned and an
additional coat of similar primer applied.
The full specified painting system shall then be re- applied and the
new paint shall overlap the existing paint by at least 50 mm all round
the affected part.
(e) Painting After Tightening Bolts
After the tensioning bolts are properly tightened the edges of the
plates around the contact areas shall be heavily coated with
Micaceous Iron Oxide paint by the Erector to prevent the ingress of
water to the unpainted contact surfaces and hence causing staining
of the steelwork later.
For connection using black bolts, the steel contact surfaces shall be
painted again before erection and connection by the Erector.
15.5 High Strength Friction Grip Bolts
(a) Bolt System
High strength friction grip bolts (H.S.F.G. bolts) to B.S. 4395 General
Grade, Part 1 shall be used in conjunction with a "Coronet", General
Grade, Load Indicating Washer (L.I. Washer) as manufactured by
cooper and Turner Limited, England, or other approved equivalent.
The term "H.S.F.G. bolts" in this Specification shall be deemed to
include a H.T. bolt, a H.T. nut, a L.I. washer and one or two H.T. flat
S15-25
or taper washers as appropriate. The L.I. washer shall be additional

to the normal washer employed and not take the place of a normal
flat or taper washer.
(b) Design Procedure, Etc.
The design procedure of General Grade H.S.F.G. bolts shall comply

with B.S. 4604: Part 1, except where this Standard conflicts with the
recommendations of the manufacturer of the L.I. washer in respect
of tightening H.S.F.G. bolts, when the manufacturer's
recommendation shall take precedence but subject to the approval
of the S.O.. The Contractor's erection drawings shall clearly indicate Formatted: Not Highlight
the correct size and length of bolt to be fitted.
The H.S.F.G. bolt system shown on the Drawings may be replaced

by other system so long as the Contractor submit detailed
calculations complying with the requirements of B.S. 4395: Part 1
and B.S. 4604: Part 1.
(c) Material
The bolts, nuts and washers shall comply with the requirements of
B.S. 4395, Part 1.
(d) Storage
The bolts, nuts and washers shall be stored in a proper dry shed and
be adequately protected from inclement weather or contamination so
that they will not deteriorate. The bolts are normally supplied by the
manufacturers with sufficient residue oil on the threads of the bolt
and nut which is not detrimental and should not removed. In this
condition they are ready for normal use, and any further treatment at
work shop or site is not recommended. If the threads, nuts and
washers are dry, rusty or dirty, they must be cleaned and
re-lubricated to reduce thread friction during bolt tightening.
S15-26
(e) Bolt Assembly
Where plane parallel surfaces are involved each H.S.F.G. bolt shall
be assembled with a flat round H.T. washer and a Load Indicating
washer under the bolt head or nut which ever is to be rotated during
tightening. The rotated bolt head or nut shall always be tightened
against a surface normal to the bolt axis.
Where the surfaces are not parallel, tapered H.T. washer are used.
Such a washer shall also be used under the non- rotated component
except where the angle between bolt axis and contact surface is
within 90 degree centigrade ± 3 degree. Tapered H.T. washers shall
be correctly positioned.
Generally, the Load Indicating washer is placed under the bolt head
with the protrusions bearing against the bolt when the nut is turned
during tightening.
If the bolt head is to be turned instead of the nut, then the Load
Indicating washer shall be placed at the nut end of the bolt assembly
with the protrusions bearing against a nut face H.T. washer between
the Load Indicator and the nut. Movement of the washer is
acceptable during tightening of the bolt but the gap should, however,
be reduced to 0.25mm for General Grade part 1 and 0.35mm for
Higher Grade Part 2 bolts. Nuts shall be placed in such a manner
that their identification marks are clearly visible after tightening.
No gasket or other flexible material shall be placed between the

steelwork. The holes shall be sufficiently well aligned to permit bolts
to be freely inserted in position. The bolts shall not be forced in
position, i.e. driving of bolts is not permitted.
(f) Tightening Procedure
It is important that all bolts and nuts shall be tightened to the

minimum shank tensions as specified by the manufacturer and to the
approval of the S.O.. Formatted: Not Highlight
S15-27
When tightening a group of bolts in a joint, there may be an

incremental loss of tension in the first ones when adjacent bolts in
the same group are being tightened due to the flexure of the steel
members. As such, the bolt may have to be retightened a second
time or more to the satisfaction of the S.O. that the required tension Formatted: Not Highlight
has been achieved.
Bolts and nuts shall always be tightened from the centre of the joint
outward when tightening a group of bolts. This will help to minimise
unwanted gap or loss of tension at the contact surface at the end of
the joint splice if the bolts are tightened progressively from one end
to the other. Retightening of the bolts shall be done as directed by
the S.O. until he is satisfied that the required shank tension has Formatted: Not Highlight
been achieved.
If after final tightening a bolt or nut is slackened off for any reason,
the bolt, nut, Load Indicator and washer or washers shall be
condemned and discarded.
The condemned bolt, nut load indicator and washer or washers shall
be removed from site and not reused.
(g) Tightening
Tightening of the bolts and control of bolt tension shall be of the

"Coronet" Load Indicator method. The Load Indicator is a specially
hardened washer with protrusions of one face which bear against
the underside of the bolt head leaving a gap or bearing against a nut
face H.T. washer between the Load Indicator and the nut is placed
at the nut end of the bolt assembly.
As the bolt is tightened the protrusions are flattened and the gap
reduced until an average gap of 0.40mm or less is achieved when
placed under a head fitting. When the Load Indicator is used with a
nut face washer, the gap should be reduced to 0.25mm for General
Grade Part 1 and 0.25mm for Higher Grade Part 2 bolts. Under no
S15-28
circumstances shall hammer be used to flatten the protrusions of the

L.T. washer in order to achieve the minimum required gap.
It is necessary to ensure that the average gap between the Load

Indicator and the bolt head or nut face washer has been reached
and this can easily be checked with a feeler gauge.
The minimum shank tension of General Grade Part 1 and Higher

Grade Part 2 H.S.F.G. bolts are given in Table 2D.
S15-29
APPENDIX TO STRUCTURAL STEEL SPECIFICATION

List of British Standards Use in Structural Steel
B.S. 4 : Structural Steel Sections
B.S. 639 : Oxy-acetylene Welding of Mild Steel
B.S. 639 : Covered Electrodes
B.S. 709 : Fusion Welded Joints and Weld Metal in Steel
B.S. 729 : Hot Dip Galvanised Coatings on Iron and Steel Articles
B.S. 916 : Black Bolts, Screws and Nuts
B.S. 1391 : Protective Schemes used in the Protection of Light Gauge Steel and
Wrought Iron against corrosion
B.S. 1449 : Steel Plate, Sheet and Strip
B.S. 1453 : Filler Materials for Gas Welding
B.S. 1494 : Fixing Accessories for Building Purposes
B.S. 2600 : Radiographic Examination of Fusing Welded Butt Joints in Steel
B.S. 2630 : Projection of Welding of Low Carbon Steel Sheet and Strip
B.S. 2994 : Cold Rolled Steel Sections
B.S. 3139 : High Strength Friction Grip Bolts for Structural Engineering
B.S. 3294 : The Use of High Strength Friction Grip Bolts in Structural Steelwork
B.S. 3410 : Metal Washers for General Engineering Purposes
B.S. 3571 : General Recommendations for Manual Inert-gas Metal-arc Welding
S15-30
B.S. 3923 : Ultrasonic Examination of Welds
B.S. 4125 : Spot Welding Electrodes and Electrode Holders
B.S. 4232 : Surface Finish of Blast-cleaned Steel for Painting
B.S. 4360 : Weldable Structural Steel
B.S. 4395 : High Strength Friction Grip Bolts (Metric Series)
B.S. 4604 : The Use of High Strength Friction Grip Bolts in Structural Steelwork
(Metric)
B.S. 4848 : Hot Rolled Structural Steel Sections
B.S. 4870)
B.S. 4871) : Approval Testing of Welding
B.S. 4872)
B.S. 5135 : Metal-arc Welding of Carbon and Carbon Manganese Steels
B.S. 5289 : Visual Inspection of Fusion Welded Joints
B.S. 5950 : Structural use of Steelworks in Building
SWEDISH STANDARD SIS 055900-1967 - Pictoral surface preparation standards for

painting steel surfaces.
S15-31

S15 - Structural Steelwork

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EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH.

, C&S AND MEP

SECTION 15 : STRUCTURAL STEELWORK

15.1 General ................................................................................... S15-11 Field Code Changed

15.1.1 Extent of Work .............................................................. S15-11

SECTION 15 – STRUCTURAL STEELWORK

15.1.1 Extent of Work

The work covered by this section of the Specification consists of

This Specification shall be read in conjunction with the standards in the

15.1.3 Testing and Inspection

numbers or identification marks on the steel, combined with a

High strength Friction Grip Bolts shall be of general grade in accordance

Mild steel Black Bolts shall comply with B.S. 916.

Electrodes used in welding shall comply with B.S. 639:1986.

15.1.5 Galvanised Work

Care shall be taken to avoid fabrication methods which could cause

15.1.5.3 Surface Preparation

Materials to be galvanized shall be thoroughly cleaned of all scale, dust and

Materials to be galvanized shall be handled with care so as to avoid any

The materials shall be dipped in a galvanizing bath of molten zinc containing

15.1.5.5 Coating Requirements

(a) Coating Weights and Thickness

The weight and thickness of the galvanizing coating shall comply

Table 15.1: Coating Weights

Minimum Average Coating on

The weight for galvanized coatings for threaded works/ fasteners

(b) Surface Finish

The galvanized coating shall be continuous, adherent, as smooth

Where a protective coating is to be applied the galvanized materials,

The galvanized coating shall be sufficiently adherent to withstand

The integrity of the galvanized coating shall be determined by visual

Any galvanizing shown to be defective on inspection or by the hammer-blow

15.1.5.7 Transport and Storage

Galvanized articles, shall, wherever possible, be transported and stored

Where required, post-treatment of galvanized products such as chromating

Where galvanized steel is to be welded, adequate ventilation shall be

Grinding of edges prior to welding may be permitted to reduce zinc oxide

All uncoated weld areas shall be reinstated as per the Coating

15.1.5.9 Coating Reinstatement

15.1.5.10 Painting for Galvanised Sundry Steelworks and Galvanised Iron

Unless otherwise specified all galvanised sundry steelwork and galvanised

(a) Galvanised Sundry Steelworks

1 coat of Etch Primer applied to the steel surfaces at a rate of 20

with clean water after application.

1 coat of Micaceous Iron Oxide Epoxy to a dried film thickness of

1 cost of Aliphatic Recoatable Two Pack Polyurethane each coat

(b) Galvanised Iron Gutter and Grating

i. Surface exposed to weather but not exposed to view

1 coat of Etch Primer applied to the steel surfaces at a rate of

down with clean water after application.

1 coat of Micaceous Iron Oxide Epoxy to a dried film

1 coat of High Built Solid Tar Epoxy to a dried film thickness

ii. Surface not exposed to weather

Coating system similar to Clause 15.1.5.10 (a) above.

(c) Galvanised Iron Downpipes

Coating system similar to Clause 15.1.5.10(a) above.

15.1.6 Working Drawings

Two copies of all detailed working drawings prepared by or on behalf of the

(The Works shall be carried in accordance with B.S. 5950).

(a) Inspection, etc.

All workmanship shall be of first class quality in every respect, the

premises of the Contractor for the purpose of inspecting work, and