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 Structural steelwork fabrication and erection Code of Practice

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ASI/HERA NZ/SCNZ
STRUCTURAL STEELWORK FABRICATION AND ERECTION CODE OF PRACTICE

OUTLINE TABLE OF CONTENTS

Page
EXPANDED TABLE OF CONTENTS SHOWING SUB-SECTIONS

Page
SECTION 1 - SCOPE

SECTION 2 NORMATIVE REFERENCED STANDARDS

SECTION 3 TERMS AND DEFINITIONS

SECTION 4 SPECIFICATIONS AND DOCUMENTATION

SECTION 5 - MATERIALS

SECTION 6 PREPARATION, ASSEMBLY AND FABRICATION

SECTION 7 - WELDING

SECTION 8 MECHANICAL FASTENING

SECTION 9 SURFACE TREATMENT AND CORROSION PROTECTION

SECTION 10 - ERECTION

SECTION 11 GEOMETRICAL TOLERANCES

SECTION 12 INSPECTION AND TESTING

SECTION 13 NON-CONFORMITIES
SECTION 14 - SITE MODIFICATIONS DURING ERECTION AND MODIFICATION AND REPAIR OF
EXISTING STRUCTURES

APPENDIX A NORMATIVE REFERENCED DOCUMENTS

APPENDIX B ADDITIONAL INFORMATION (Normative)

APPENDIX C GUIDANCE FOR THE DETERMINATION OF THE CONSTRUCTION CATEGORY

(informative)
APPENDIX D CHECK LIST FOR THE CONTENT OF A QUALITY PLAN (Informative)

APPENDIX E GEOMETRICAL TOLERANCES (Normative)

APPENDIX F STANDARD TEST FOR EVALUATION OF SLIP FACTOR (Normative)

APPENDIX G INSPECTION OF BOLT TENSION USING A TORQUE WRENCH (Informative)

APPENDIX H PROVISIONS APPLYING TO NEW ZEALAND ONLY (Normative)

SECTION 1 SCOPE

1.1 Purpose

1.2 Structural elements included

Structures and sub-structures

Components and elements

1.3 Structural elements excluded

SECTION 2 NORMATIVE REFERENCED STANDARDS

2.1 General

2.2 Primary references

2.2.1 Design

2.2.2 Fabrication and erection

2.2.3 Surface treatment and corrosion protection

2.2.4 Quality management

SECTION 3 TERMS AND DEFINITIONS

3.1 General

Authority -

Builder

Component -

Construction works

Construction

Constructor

Construction Category

Construction specification

Designer

Erector

Fabrication

Fabricator

Importance level

Manufacturer

Material -
Non-conformity -

Non-slip fasteners -

Preparation and assembly -

Quality -

Structure -

Stability limit state -

Strength limit state -

Structural steelwork

Supplier

Supplier declaration of conformity (SDOC)

Tensile strength -

Tolerance

Works

Yield stress -

3.2 Types of tolerance

Fundamental tolerance -

Manufacturing tolerance -

Fabrication tolerance
Erection tolerance -

3.3 Connection types using mechanical fasteners

Bearing-type connection -

Friction-type connection - c

Full tensioning -

Snug tight -

3.4 Welded connections

Complete penetration butt weld

Incomplete penetration butt weld -

Fillet weld -

3.5 Traceability

Full traceability:
Partial traceability:

Basic traceability:

3.6 Types of inspection

First-party inspection
Second-party inspection

Third-party inspection
SECTION 4 SPECIFICATIONS AND DOCUMENTATION

4.1 Construction specification

4.1.1 General

4.1.2 Construction Category

NOTE: the requirements for Construction Category CC4 are additional to CC3. The additional requirements are
not fully defined in this Code of Practice. CC4 applies to unusual or special structures for which it is expected that
requirements additional to those for CC3 will be defined at a project specific level.

4.1.3 Geometrical tolerances

4.2 Use of Building Information Modelling

4.3 Shop detailing documentation

4.3.1 Responsibility

4.3.2 Scope of documentation

4.3.3 Fabricator-produced shop detail documentation

4.3.4 Shop detail documentation not produced by the fabricator

4.3.5 Approval process for shop detail documentation

documentation

4.4.1 Quality documentation

4.4.2 Quality plan

4.4.3 Safety of the works during erection

4.4.4 As-built documentation

SECTION 5 MATERIALS

5.1 General

5.1.1 Application

5.1.2 Quality Management System

5.2 Designation, documentation and traceability

5.3 Steels

5.3.1 General

NOTE: The following Standards are cited as complying Standards in both AS 4100 and NZS 3404.1

Australian and New Zealand Joint Standards

Australian Standards

NOTE: Additional steel Standards included in NZS 3404.1 and which may be used in conjunction with this Code
of Practice in NEW ZEALAND ONLY are listed in Appendix H, Clause H.1.

5.3.2 Thickness tolerances

5.3.3 Surface condition

NOTE: Different metallic coated spangle finishes are generally aesthetic in nature and do not impact structural
properties. Continuously hot-dip metallic coated steels used in structural application are typically not skin passed.

5.3.4 Special requirements

NOTE: Ultrasonic examination will not typically detect inclusions or internal discontinuities normally associated
with lamellar tearing (e.g. manganese sulphides) and is hence not an indicator of through-thickness ductility.

5.4 Welding consumables

5.5 Mechanical fasteners

5.5.1 Corrosion resistance

5.5.2 Terminology

Washer --
Assembly -

5.5.3 Structural fasteners for other than tensioned applications

5.5.4 Structural bolt assemblies for tensioned applications

NOTE: AS/NZS 1252 is based on, and except for the marking requirements for the nuts and bolts, is technically
equivalent to the following ISO Standards: ISO 4775:1984 (nuts), ISO 7411:1984 (bolts), ISO 7415:1984
(washers).

5.5.5 Direct tension indicators

5.5.6 Weather resistant assemblies

NOTE: Type 3 Grade A fasteners to ASTM A325 would be suitable.

5.5.7 Foundation bolts

5.5.8 Locking devices

5.5.9 Tapered washers

5.5.10 Fasteners for thin gauge components

5.5.11 Special fasteners

5.5.12 Delivery, identification and documentation

5.6 Mechanical and chemical anchors

5.7 Studs and shear connectors

5.8 Explosive fasteners

5.9 Grouting materials

5.10 Storage of materials
SECTION 6 PREPARATION, ASSEMBLY AND FABRICATION

6.1 General

6.1.1 Application

6.1.2 Quality management system

NOTE: The level of documentation will generally increase with the Construction Category from CC1 to CC4.

6.1.3 Safety plan

Electrical safety

Protective equipment

6.1.4 Work method statements

6.1.5 Steelwork to be painted or galvanized

6.1.6 Architecturally exposed structural steelwork

6.2 Identification and traceability

6.3 Handling and storage

6.4 Cutting

6.4.1 Methods of cutting

6.4.2 Roughness of cut

TABLE 6.4

MAXIMUM CUT SURFACE ROUGHNESS

Construction Category Maximum roughness CLA Method

(micrometers)

t t

t t

6.4.3 Re-entrant corners

 °
NOTE: a re-entrant corner is a corner in which the open angle between the cut faces is less than 90

6.4.4 Cut edges to be painted

NOTE: Clause 9.9.5 also covers rolled edges

6.5 Shaping

°
NOTE: Heating hollow section members complying with AS/NZS 1163 above 620 C, may adversely affect the
material properties.

6.6 Holing

6.6.1 Holing methods

fy) f
6.6.2 Circular hole diameters

6.6.3 Oversize and slotted hole sizes

6.6.4 Limitations on use of oversize and slotted holes

Oversize hole

Short slotted hole

Long slotted hole

NOTE: The onstruction pecification should state which connections are friction-type and which are bearing-
type. If not so stated, the design engineer should be contacted for clarification. The use of short and long slotted
holes is also restricted by the direction of loading in AS 4100 and the design engineer should select the use of
such holes accordingly and make it clear in the construction specification that the holes can be slotted and in
which direction the slots may run. All questions about the use of such holes should be directed to the design
engineer.

6.6.5 Countersinking

6.6.6 Holes for pin connections

6.7 Full contact bearing surfaces

6.8 Assembly
6.9 Assembly check

6.10 Transit to site

6.11 Supervision
SECTION 7 WELDING

7.1 General

7.1.1 Quality requirements

Notes to Australian requirements:

1. For CC1, fabricators complying with AS/NZS ISO 3834 Part 4 should note that the normative
requirements of the relevant part of AS/NZS 1554 exceed those of AS/NZS ISO 3834.4 and must be
complied with.
2. For CC2, compliance of the fabricator with all normative requirements of the relevant part of AS/NZS
1554 should be verified by a second-party audit.
3. For CC3 and CC4, compliance of the fabricator with all normative requirements of the relevant part of
AS/NZS 1554 should be verified by a third-party audit.

Notes to New Zealand requirements:

1. For CC2, compliance of the fabricator with all normative requirements of AS /NZS 1554.1 shall be
verified by a third-party audit in addition.
2. The fabricator shall be certified by a third-party audit to AS/NZS ISO 3834 Part 2.

NOTE: Guidelines for the implementation of a quality management system in accordance with AS/NZS ISO
3834 for fusion welding of steel may be found in ISO/TR 3834-6.

7.1.2 Welding requirements

7.1.3 Requirements of construction specification

7.2 Welding plan

7.2.1 Requirement for a welding plan

7.2.2 Content of a welding plan

7.2.3 Safety plan

and allied operations and guidance on safe practices along with a brief explanation of such practices.

7.3 Welding processes

7.4 Qualification of welding procedures

TABLE 7.4.

7.5 Qualification of welding personnel

7.5.1 Qualification of welders

7.5.2 Welding supervision

TABLE 7.5

Construction category
Description CC1 CC2 CC3 CC4
7.6 Joint preparation

NOTE: Mill edge plates and coil steels may contain surface discontinuities near the as-rolled surfaces. Sufficient
edge trim should be removed to avoid these areas being included in a weld preparation. Advice should be sought
from the product manufacturer regarding the minimum amount of edge trim that should be removed.

7.7 Weld types

7.7.1 Fillet welds

7.7.2 Butt welds

7.7.3 Seal, slot and plug welds

7.7.4 Arc spot welds for light gauge components

7.7.5 Resistance spot welds for light gauge components

7.8 Storage and handling of welding consumables

7.9 Execution of welding

7.9.1 Assembly for welding

7.9.2 Preheating
7.9.3 Weather protection during welding

7.9.4 Tack welds

7.9.5 Back gouging

7.9.6 Temporary attachments

NOTE: The relevant parts of AS/NZS 1554 have limits on the depth of grinding allowed.

7.9.7 Arc strikes

7.9.8 Weld spatter

7.9.9 Interrun cleaning

NOTE: Where cracks are noticed during welding, the welding process should be stopped and the reason for
cracking investigated.

7.9.10 Cleaning of finished welds

7.9.11 Dressing of butt welds

7.9.12 Post-weld heat treatment

7.9.13 Welds on steels with improved weather resistance

7.9.14 Welds on steel to be painted or galvanized

NOTE: The use of anti-spatter sprays and compounds should be avoided on steelwork to be painted or
galvanised unless it can be established that their use does not interfere with coating adhesion.

7.9.15 Welds on architecturally exposed structural steelwork.

7.9.16 Stud welding

7.10 Acceptance criteria

NOTE: WTIA Technical Note 10 gives guidance on the use of fracture mechanics analyses in the assessment of
the effects of imperfections. WTIA Technical Note 10 or BS 7910 may be used to evaluate the acceptability of
imperfections.
SECTION 8 MECHANICAL FASTENING

8.1 General

8.1.1 Application

8.1.2 Quality management system

8.1.3 Safety plan

8.1.4 Work method statements

8.2 Bolts, nuts and washers

8.2.1 General
8.2.2 Bolts

8.2.3 Nuts

8.2.4 Washers
8.2.5 Storage

8.3 Snug-tightening of bolts

8.4 Preparation of contact surfaces on connected plies

8.4.1 General

8.4.2 Friction-type connection

NOTE: Draft AS/NZS 2312.1 contains information on the effect of paint coating systems on the friction coefficient.
Generally, all systems will require testing.

NOTE: it is not necessary to completely remove hot-dip galvanized coatings in order to obtain an adequate
friction coefficient. However, the testing specified above should reflect as accurately as possible the actual
treatment to be given to the galvanized surface. Consideration also has to be given to the possibility of long-term
slip or creep occurring. Further information is available from the Galvanizers Association of Australia or the
Galvanizing Association of New Zealand.
8.5 Tensioning of high strength bolts

8.5.1 Trained personnel

8.5.2 Snug-tightening

8.5.3 Tensioning pattern

8.5.4 Re-tensioning

8.5.5 Minimum bolt tension

TABLE 8.5.5

MINIMUM BOLT TENSION

Nominal diameter of Minimum bolt tension

bolt kN
8.5.6 Part-turn method of tensioning

TABLE 8.5.6

NUT ROTATION FROM THE SNUG-TIGHT CONDITION

Disposition of outer face of bolted parts

(see Notes 1, 2, 3 and 4)
Bolt length One face normal
(underside of head to end of Both faces to
bolt) Both faces
normal to bolt axis and
sloped
bolt axis other
sloped

8.5.7 Tensioning by the use of direct-tension indication device

8.5.8 Use of compressible washer-type direct tension indicators

8.6 Fastening of thin gauge components

8.7 Use of specialised fasteners and fastening methods

8.8 Installation of mechanical and chemical anchors

8.8.1 Construction specification

8.8.2 General requirements

8.8.3 Technical information

8.8.4 Trained personnel

8.8.5 Installation

8.8.6 Holes

NOTE: some chemical anchors do not function in diamond drilled holes due to the smooth sides of the holes.
8.8.7 Curing of chemical anchors

8.8.8 Tightening

8.8.9 Conformance to construction specification

8.8.10 Storage and handling

NOTE: elevated temperature has a deleteriou

recommendations as to storage temperature should be complied and when elevated temperature occurs beyond
the recommended temperature, advice should be sought from the manufacturer.

8.8.11 Hitting reinforcement in concrete elements

NOTE: BS 8539 permits a lesser distance for a new hole from an aborted hole subject to detailed instructions
being complied with. BS 8539 should be consulted for details.

8.8.12 Anchors in masonry

NOTE: correctly installed chemical anchors avoid damage to masonry since they do not exert expansive
pressure on the masonry.

NOTE 1: In general, anchor manufacturers advise against the installation of anchors of either type in the mortar.
BS 8539 provides detailed guidance on where anchors should be set in masonry and should be consulted for
details.

NOTE 2: The suitability of the anchor system for use with hollow bricks or blocks should be checked with the
manufacturer before being used. Additional special components may be required.

8.9 Supervision
SECTION 9 SURFACE TREATMENT AND CORROSION PROTECTION

9.1 General

9.2 Planning

9.2.1 Quality management system

9.2.2 Safety plan

Electrical safety

Protective equipment
9.2.3 Work method statements

9.2.4 Reviews

NOTE: Clause 11.3 of AS/NZS 2312 provides guidance on -

Painting

NOTE: The use of the relevant inspection forms contained in AS 3894 Parts 10 to 14 is recommended.
Galvanizing

NOTE: Galvanizing is a process for which the surface preparation is an intermediate step which is integral to the
manufacturing Standard AS/NZS 4680. It is not usual to include an inspection stage in the WMS requiring the
operator to inspect the steel beyond a visual inspection before galvanizing.

9.2.5 Traceability

9.3 Preparation of steel surfaces

9.3.1 General

9.3.2 Capabilities of personnel

9.3.3 Surfaces intended to be painted

NOTE: Methods of test to determine whether a surface is free of oil, grease and salt contamination are given in
AS 3894.6.

NOTE: Four grades of blast clean surfaces are given in ISO 8501-1, namely classes Sa1, Sa2, Sa2.5, Sa3. Class
extent that
only traces remain in the form of spots or stripes, and the surface shows varying shades of grey. Class Sa1 is

9.3.4 Surfaces intended to be galvanized

NOTE: This Code of Practice does not include hot-dip galvanizing of continuous sheet coil and cold-formed
shapes covered by AS/NZS 4792, nor electro-galvanized zinc coatings applied to hollow and open sections
covered by AS/NZS 4750.

9.3.5 Surfaces for other coating systems

9.3.6 Supervision of surface preparation

9.3.7 Weather resistant steel surfaces

NOTE: In order to assist in the formation of the protective patina and provide a uniform finish, it is recommended
that after fabrication and prior to erection, all weathering steel components should be abrasive blast cleaned to
SSPC-SP 6/NACE No 3 to remove mill scale and other contaminants. This should be immediately followed by a
minimum of three cycles of wetting using potable water and drying.

9.3.8 Contact surfaces in connections using mechanical fasteners

9.3.9 Surfaces in contact with concrete

NOTE: Structural steel members that are to be galvanized will normally be coated for the full length of the
member. It is often not economic (and often not possible) to specify for only part of a member length to be
galvanized while the remainder remains ungalvanized. However, there are situations, such as where shear studs
are intended to be welded post-galvanizing, where a heat resistant paint may be applied prior to galvanizing to
inhibit adherence of the galvanized coating and ensure the surface remains essentially zinc free.

9.4 High pressure water cleaning

9.4.1 General

9.4.2 Equipment

9.4.3 Water

9.4.4 Flash rusting

9.5 Abrasive blasting

9.5.1 General
9.5.2 Equipment

9.5.3 Restrictions

9.5.4 Surface finish

9.5.5 Precautions after preparation

9.6 Mechanical cleaning

9.6.1 Surface requirements

-1 and
SP2, SP3 and SP11 is illustrated in SSPC-VIS 3. Bright steel is defined as a shiny surface free from rust, scale or
other harmful imperfections.

9.6.2 Procedure

9.6.3 Precautions after preparation

9.6.4 Final cleaning

9.7 Sealing of enclosed spaces

9.7.1 General

NOTE: Cracks in seal welds which are not detectable by visual inspection may allow moisture to penetrate
through a seal weld.

9.7.2 Overlapping surfaces

9.7.3 Penetration by fasteners

9.7.4 Closed and hollow sections

NOTE: Guidance on the extent of vent and drain holes for hollow sections may be found in Ssubclause C6.2 of
AS /NZS 4680 and Section 1
9.8 Inaccessible surfaces

9.9 Fabrication and welding considerations

9.9.1 Responsibility

9.9.2 Welds

NOTE: Note 3 to Table 6.2.2 of AS/NZS 1554.1 contains a warning that where allowance for overlap and surface
pores are detrimental to any surface treatment, they may not be acceptable for that surface treatment. Such
imperfections may either need to be filled (in the case of a painted finish see Clause 9.9.3) or may need to be
repaired by being ground out and repair welded (in the case of galvanized finish and possibly for a paint finish).

9.9.3 Rectification
9.9.4 Treatment grades

nts in ISO 8501-3 except that

Grade P2 has a requirement for a chamfer which is not included in ISO 8501-3.

visual inspection alone is assumed. To achieve a 2 mm radius a minimum of three passes of grinding is usually
required.

NOTE 3: Rolled edges include edges of universal sections and channels and slit edges of plates.

9.9.5 Cut edges

9.9.6 Precoated steel

9.10 Application of paint coatings

9.10.1 General

9.10.2 Capabilities of personnel

9.10.3 Safety
9.10.4 Paint material

9.10.5 Quality control of paint material

9.10.6 Information required

9.10.7 Mixing of paint

9.10.8 Use of thinners

9.10.9 Tinting

9.10.10 Masking
9.10.11 Painting conditions

Note 1: AS 3894.7 covers measurement or surface temperature and ISO 8502-4 provides guidance on the
probability of condensation.

Note 2: Clause 7.6 of AS/NZS 2312.1 contains a discussion of painting conditions.

9.10.12 Priming

9.10.13 Spray painting equipment

9.10.14 Spray application

9.10.15 Brush and roller application

9.10.16 Testing equipment

9.10.17 Measurement of film continuity

9.10.18 Measurement of degree of cure

9.10.19 Corrosion protection of fasteners

NOTES:

1. The durability of the fasteners provided by the corrosion protection system should match that for the
structure the fasteners are used on.
2. In aggressive environments or where maintenance access is difficult, a life cycle costing approach may
suggest the use of fasteners in alternative materials, such as stainless steel.

9.10.20 Storage, handling and transport

9.10.21 Supervision of painting

9.11 Application of galvanized coatings

9.11.1 General

NOTE: This Code of Practice does not include hot-dip galvanizing of continuous sheet coil and cold-formed
shapes covered by AS/NZS 4792, nor electro-galvanized zinc coatings applied to hollow and open sections
covered by AS/NZS 4750.

NOTE 1: Preferred designs of articles suitable for hot-dip galvanizing may be found in Appendix A of AS/NZS
2312.2 and recommended design information is contained in Appendix C of AS/NZS 4680..

NOTE 2: See also Clause 9.11.5 below.

9.11.2 Surface preparation

9.11.3 Steel material

NOTE: The mechanical properties of the structural steels most commonly galvanized are not affected by the
galvanizing process.
NOTE: Appendix D of AS/NZS 4680 contains information on the properties of steel which can affect or be
affected by hot-
Table 8.1 of AS/NZS 2312.2 also contains information related to steel composition and suitability for galvanizing.
Different steel compositions affect the coating thickness and the initial surface finish.

9.11.4 Fabrication considerations for galvanizing

NOTE: Guidance on fabrication issues

sought in relation to these issues.

9.11.5 Galvanizing method

9.11.6 Appearance of coating and freedom from defects

9.11.7 Coating mass and thickness

NOTE: The normal inspection method is by using a magnetic measuring device. Guidance on the use of
magnetic gauges may be found in AS 2331.1.3 and AS 2331.1.4. Field testing of coating thickness is also
covered by AS 3894.3.

9.11.8 Adherence of coating

9.11.9 Repair after galvanizing

9.11.10 Storage handling and transport

NOTE 1: Such control measures might include storage such that free air movement is allowed across the
surfaces of the work, the use of spacers to minimise contact areas between items, or the avoiding of close
nesting of the work.

NOTE 2: The development of wet-storage staining is not to be a cause for rejection see AS/NZS 4680
provided that the zinc coating thickness remains above the specified minimum requirements.

NOTE 3: Guidance on the issue of wet-storage stain may be found in Appendix F of AS/NZS 4680.

9.11.11 Supervision

9.12 Painting of galvanized coatings

9.12.1 Treatment of galvanized surface

9.12.2 Procedure for sweep blasting

9.12.3 Painting

NOTE: Examples of suitable paint systems for galvanized steel may be found in Table 6.1 of AS/NZS 2312.2.

9.13 Other coating methods

9.14 Third-party inspection

9.15 Repairs to corrosion protection

9.15.1 Painted surfaces

9.15.2 Paint affected by on-site welding

9.15.3 Galvanized surfaces

9.16 Architecturally exposed structural steelwork

9.16.1 General requirements

9.16.2 Categories of AESS

NOTE: For AESS C, the AESS matrix in Table 27 of NZS 3404.1:2009 may be used in order to specify required
treatment.

9.16.3 Construction specification information

9.16.4 Additional fabrication requirements for AESS

9.16.5 Additional erection requirements for AESS

9.17 Cathodic protection

9.18 Galvanic coupling

NOTE: A discussion of bimetallic contact is contained in Clause B8 of Appendix B of AS/NZS 2312.2.

SECTION 10 ERECTION

10.1 General

10.2 Site planning

10.2.1 Safety Plan

Electrical safety

Protective equipment
10.2.2 Quality management system

10.2.3 Work method statement

10.2.4 Risk assessment

10.2.5 Lifting equipment and associated personnel

10.3 Site survey

10.4 Erection methods

10.4.1 Equipment support

10.4.2 Erection loads

10.4.3 Temporary members

10.4.4 Handling and storage

10.4.5 Assembly and alignment

10.4.6 Architecturally exposed structural steelwork

10.5 Supports

10.5.1 Suitability of permanent supports

10.5.2 Bearings, anchor bolts and anchoring devices

10.5.3 Temporary supports

10.5.4 Grouting or mortaring at supports

10.6 Erection drawings

10.7 Erection work at site

10.8 Supervision
SECTION 11 GEOMETRICAL TOLERANCES

11.1 General

11.2 Measurement

11.3 Non-compliance of fundamental tolerances

11.4 Non-compliance of other than fundamental tolerances
SECTION 12 INSPECTION AND TESTING

12.1 General

12.2 Inspection

12.3 Inspection of materials

12.3.1 Inspection and Test Plan

NOTE: The ITP requirements for Construction Category CC2 may not be as extensive as that for CC3 or CC4.
12.3.2 Qualifications of inspectors

12.3.3 Structural steels

NOTE: For Construction Categories CC1 and CC2, the requirement to comprehensively check the
documentation may be reduced where third-party certification or a Supplier Declaration of Conformity (SDOC) is
obtained specifically covering the stated material. Where the material is third-party certified or an SDOC is
obtained, the material test certificates may be inspected for material type, size and grade only, to ensure
compliance with the construction specification. For Construction Categories CC3 and CC4, all documentation
must be comprehensively checked to ensure the material is valid and compliant.

12.3.4 Metallic coated steels

12.3.5 Prefabricated components

NOTE: This Subclause applies to all part-fabricated components delivered to the
in a fabricated item and to prefabricated components delivered directly to site for erection, if these components
are not fabricated by the abricator.

12.3.6 Non-conforming steel or components

NOTE: AS 4100, AS/NZS 4600, AS 5100 and NZS 3404:1 require that unidentified steel be assumed to have a
yield stress of 170 MPa.

12.3.7 Testing of non-conforming steel or components

NOTE: Appendix D of BS EN 1990:2002

design values based on statistical sampling.

12.3.8 Offcuts or unused material

12.4 Measurement of fabricated and erected components

12.5 Inspection of preparation and assembly

12.5.1 Inspection and test plan

12.5.2 Qualifications of the inspector

12.5.3 Results of inspections

12.6 Inspection of welding

12.6.1 Inspection requirements

TABLE 12.6

Construction category
Description CC1 CC2 CC3 CC4

NOTES:
1. The minimum extent of non-destructive testing should be specified on the engineering drawings or
within the contract documentation.
2. AS/NZS ISO 3834 parts 2 and 3 requires documented first party inspection as a minimum throughout
the fabrication process.

12.6.2 Inspection and test plan for welding

12.6.3 Qualifications of welding inspectors
12.6.4 Results of welding inspections

12.6.5 Requirements in the construction specification for welding inspections

12.6.6 Degree of welding inspection

NOTE: The provisions of the AS/NZS series of Standards in respect of welding procedures and workmanship are
such that satisfactory welds should be achieved as a matter of course if followed correctly. In keeping with this
philosophy, the relatively low levels of weld inspection nominated in the AS/NZS 1554 series of Standards may
be applied successfully in practice, provided that documented inspection is carried out to ensure that the welding
procedures required by the AS/NZS 1554 series of Standards are being correctly followed.

NOTE: For example, if an overall requirement of 10% of welds are to be examined ultrasonically, 20% of the
initial welds including a minimum of one weld of each welder should be tested until it is established that the
welding is being done satisfactorily. The amount of inspection can then be dropped off to random spot checking if
the welding remains satisfactory. An overall inspected weld length of 10% approximately can be achieved by
suitable manipulation of the extent of spot checking.
NOTE: If not stated in the construction specification, Section 12.6.10 contains suggested extents of visual
scanning, visual inspection, magnetic particle or liquid penetrant inspection, radiographic or ultrasonic
examination. This guidance may be used in the absence of information in the construction specification.

12.6.7 Timing of weld inspections

Hold time
c
Weld size Heat input Q (hours)
a b
(mm) (kJ/mm) d Steel type 8Q and
Steel types 1 to 8
above
S
S

DTT t

Q
12.6.8 Visual inspection of welds

12.6.9 Non-destructive examination (NDE) of welds

12.6.10 Extent of non-destructive examination (NDE) of welds

Category Visual Other

12.6.11 Correction of weld defects

Note: For methods of fracture assessment and guidance on the effects of imperfections, see BS 7910
and WTIA Technical Note 10.
12.6.12 Inspection of welded shear studs

12.7 Inspection of mechanical fastening

12.7.1 Inspection and Test Plan

12.7.2 Qualifications of inspectors

12.7.3 Results of inspections

12.7.4 Inspection of fastener quality

12.7.5 Testing of non-conforming mechanical fasteners

12.7.6 Inspection of snug-tightened fasteners

12.7.7 Inspection of tensioned high strength bolts

NOTES:
1.
direct-tension indicating device.
2. The use of a torque wrench for inspection is considered suitable only to detect gross under -
tensioning. A procedure for such use is contained in Appendix G.

NOTE: ISO 2859-5 gives two methods for establishing sequential sampling plans, the numerical method and the
graphical method. The graphical method should be applied for fastener inspection.

12.7.8 Inspection of fasteners in thin-gauge components

NOTE: Replacement screws may need to be of a larger diameter in order to ensure secure fixing in the pre-
formed hole and the advice of the screw manufacturer should be sought in this regard.

12.7.9 Inspection of specialised fasteners and fastening methods

12.7.10 Inspection of mechanical and chemical anchors

12.8 Inspection of surface treatment

12.8.1 Inspection and Test Plan

12.8.2 Qualifications of inspectors

12.8.3 Results of inspections

12.8.4 Pre-painting condition reports

12.9 Inspection of paint coatings

12.9.1 Inspection and test plan

12.9.2 Qualifications of inspectors

12.9.3 Results of inspections

12.9.4 Daily inspection report

12.9.5 Inspection after priming

12.9.6 Measurement of dry film thickness.

12.9.7 Identification and treatment of defects

12.10 Inspection of galvanized coatings

12.10.1 Means of demonstrating compliance with Standard

12.10.2 Results of inspections

12.11 Inspection of erection

12.11.1 Inspection and test plan

12.11.2 Qualifications of the inspector

12.11.3 Results of inspections

12.11.4 Survey methods and accuracy

NOTE: When comparing measurements against specified tolerances, the following should be considered:

1) Inherent tolerances exist in optical and electronic equipment;

2) Steel tapes require corrections for sag, tension, slope and temperature;
3) Axial shrinkage of columns will occur due to dead loads and construction loads and should be
considered when comparing floor levels with external bench marks;
The effect of permissible rolling and fabrication tolerances should be considered as to their effect on
erection tolerances.
12.11.5 System of measurement

NOTES:

1. Any system does not need to set out explicit requirements for secondary structural members such as
door posts, purlins and girts, unless called for in the construction specification.
2. As an alternative to assessing the permissible deviations for the overall structure based on Appendix E,
for large or unusual structures, an alternative approach, such as the square root of the sum of the
squares (SRSS) method specified in BS 5606, may be used.

12.11.6 Reference points and levels

12.11.7 Location and frequency of measurements

12.12 Inspection of secondary structural elements

12.12.1 Scope

12.12.2 Installation

12.12.3 Results of inspections

SECTION 13 NON-CONFORMITIES

13.1 Definition

13.2 Fabricated items

13.3 Erected items

13.4 Action on non-conformity
SECTION 14 SITE MODIFICATIONS DURING ERECTION AND MODIFICATION AND REPAIR OF
EXISTING STRUCTURES

14.1 General

14.2 Site modification of fabricated steelwork

14.3 Materials

Note: the identification of all elements should be determined from existing drawings or specifications where
possible and should be confirmed by site inspection.
14.4 Loading during operations

14.5 Cleaning

14.6 Welding

14.7 Heat straightening

14.8 Testing and inspection

14.9 Replacement of rivets

14.10 Replacement of mechanical fasteners

APPENDIX A - NORMATIVE REFERENCED DOCUMENTS

A.1 General

A.2 Steels (see Clause 5.3)

A.2.1 Australian and New Zealand Joint Standards

A.2.2 Australian Standards

A.3 Welding consumables (See Clause 5.4 and Section 7)

A.3.1 Australian and New Zealand Joint Standards

A.3.2 International Standards Organisation Standards

A.4 Mechanical fasteners (see Clause 5.5 and Section 8)

A.4.1 Australian and New Zealand Joint Standards

A.4.2 Australian Standards

A.4.3 American Society for Testing and Materials Standards

A.4.4 International Standards Organisation Standards

A.5 Preparation, assembly and fabrication (see Section 6)

A.5.1 British Standard

A.5.2 International Standards Organisation Standard

A.6 Welding (see Section 7)

A.6.1 Australian and New Zealand Joint Standards

A.6.2 Australian Standards

A.6.3 International Standards Organisation Standards

A.6.4 Welding Technology Institute of Australia

A.6.5 British Standard

A.7 Mechanical fastening (see Section 8)

A.7.1 Australian Standards

A.7.2 British Standard

A.7.3 European Standard

A.7. Research Council on Structural Connections

A.8 Surface treatment (see Section 9)

A.8.1 Australian Standards

A.8.2 International Standards Organisation Standards

A.8.3 Structural Steel Painting Council Standards

A.8.4 British Standard

A.8.5 Australian Steel Institute publication

A.9 Corrosion protection (see Section 9)

A.9.1 Australian and New Zealand Joint Standards

A.9.2 Australian Standards

A.10 Erection

A.10.1 Australian Standard

A.11 Tolerances

A.11.1 European Standard

A.11.2 British Constructional Steelwork Association Publication

A.12 Inspection and Testing

A.12.1 Australian Standards

A.12.2 Australian and New Zealand Joint Standards

A.12.3 International Standards Organisation Standards

A.12.4 British Standard

A.12.5 Structural Steel Painting Council Standards

A.12.6 American Society for testing and Materials Standard

A.13 Design and documentation

A.14 Quality management

A.15 Miscellaneous
 APPENDIX B - ADDITIONAL INFORMATION

B.1 Required additional information

NOTE: The information provided in Table B.1 is intended to form the basis for the items to be addressed in the
construction specification prepared for the project.

Clause Additional information required

4 Specification and documentation

5 Materials

6 Preparation, fabrication and assembly

7 Welding

8 Mechanical fastening

9 Surface treatment and corrosion protection

10 Erection

12 Inspection and testing

Section 13 Non-conformities

B.2 List of options to be selected

NOTE: The information provided in Table B.2 is intended to form a checklist of items for review and, where
appropriate, inclusion in the construction specification for the project.

Clause Option(s) to be selected

4 Specification and documentation

5 Materials
6 Preparation, fabrication and assembly

7 Welding

8 Mechanical fastening

9 Surface treatment and corrosion protection

10 Erection

12 Inspection and testing

B.3 Responsibilities to be assigned

Clause Responsibility to be assigned
4 Specifications and documentation

8 Mechanical fastening

9 Surface treatment and corrosion protection

10 Erection

12 Inspection and testing

13 Non-conformity

14 Site modification and modification and repair of existing structures

B.4 Requirements related to the Construction Categories

2
Clause CC1 CC2 CC3 CC4
NOTES:

1.
Code of Practice and any requirements required by the construction specification are still applicable.
2. The requirements for Construction Category CC4 are additional to CC3 but not fully defined in this Code
of Practice. CC4 applies to unusual or special structures for which it is expected that requirements
additional to those for CC3 will be defined at a project specific level.
 APPENDIX C - GUIDANCE ON DETERMINATION OF THE CONSTRUCTION CATEGORY

(INFORMATIVE)

C.1 Background

C.2 Introduction

NOTE: The process outlined for defining a Construction Category is consistent with the philosophy and principles
on which AS/NZS 1170.0 is based and intended to provide a level of consistency between the basis for the
design assumptions and those for the ensuing fabrication and erection for the building or structure.
The determination of the Construction Category is undertaken in the design phase, based on the known loading
for the building, the intended function, what maintenance and inspection measures will be in place, the elements
that comprise the structure and the expected complexity of fabrication or erection for the structure. The
construction specification should embody the specifics of these decisions and the additional and optional
information necessary to fully define the requirements for the chosen Construction Category or categories.

C.3 Input factors determining the choice of Construction Category

C.3.1 General

C.3.2 Importance factor

NOTE: There is no provision in the BCA or in AS/NZS1170.0 for designating parts of a structure with different
importance factors.

C.3.3 Service category

Service category Criteria

NOTE: The Service Category is also used to assess the recommended extent of non-destructive examination
(NDE) of welds (see Section 12.6.10) and therefore should be nominated in the Construction Specification.

C.3.4 Fabrication category

Fabrication category Criteria

C.4 Determination of the Construction Category

Importance level 1 2 3 4
Service categories SC1 SC2 SC1 SC2 SC1 SC2 SC1 SC2
Fabrication FC1
categories FC2
NOTE: The determination of the Construction Category is the responsibility of the designer, taking national
provisions, published guidance from industry associations and the relevant Work, Health and Safety regulations
and Codes of Practice into account.
 APPENDIX D CHECKLIST FOR THE CONTENT OF A QUALITY PLAN

(INFORMATIVE)

D.1 Introduction

D.2 Content

D.2.1 Management

D.2.2 Specification review

D.2.3 Documentation

D.2.3.1 General

D.2.3.2 Documentation prior to execution

D.2.3.3 Construction records

D.2.3.4 Retention of Documentary records

D.2.4 Inspection and testing procedures

 APPENDIX E GEOMETRICAL TOLERANCES

(Normative)

E.1 Manufacturing tolerances

E.2 Fabrication tolerances

E.3 Erection tolerances

NOTE: In the above Tables, some tolerances are identified with (F) which indicates that the tolerance is
FUNDAMENTAL because the tolerance is a geometrical tolerance necessary to satisfy the design assumptions
for a structural element or component in terms of design capacity of that structural element or component as
defined in the design Standards AS 4100, AS 2327.1 or NZS 3404.1.
E.1 MANUFACTURING TOLERANCES

STRUCTURAL SECTIONS AFTER MANUFACTURE

No. Criterion Parameters Perm

TABLE E.1.2

LIGHT GAUGE PROFILES AFTER MANUFACTURE

No. Criterion Parameters

 TABLE E.1.3

STRUCTURAL DECKING AFTER MANUFACTURE

No. Criterion Parameters

E.2 FABRICATION TOLERANCES

TABLE E.2.1

MANUFACTURED WELDED I SECTIONS AFTER FABRICATION AND ROLLED SECTIONS

AFTER FABRICATION (HOT ROLLED OR COLD FORMED)

No. Criterion Parameters

 TABLE E.2.2

ELEMENTS OF FABRICATION OF COMPONENTS AND MEMBERS

No. Criterion Parameter

 TABLE E.2.3

FABRICATED THREE PLATE SECTIONS

No. Criterion Parameter

 TABLE E.2.4

FABRICATED BOX SECTIONS

No. Criterion Parameter

 TABLE E.2.5

FABRICATED TRUSSES AND TRUSS ELEMENTS

No. Criterion Parameter

E.3 ERECTION TOLERANCES

TABLE E.3.1

FOUNDATIONS AND FOUNDATION BOLTS

No. Criterion Parameter

 TABLE E.3.2

FRAME SETOUT

No. Criterion Parameter Permitted deviation

 TABLE E.3.3

COLUMNS

No. Criterion Parameter

 TABLE E.3.4

BEAMS

No. Criterion Parameter

TABLE E.3.5

CRANE RUNWAY GIRDERS

No. Criterion Parameter

 APPENDIX F STANDARD TEST FOR EVALUATION OF SLIP FACTOR

(Normative)

F.1 Test specimens

F.2 Instrumentation

F.3 Method of testing

F.4 Slip load

F.5 Slip factor

 APPENDIX G INSPECTION OF BOLT TENSION USING A TORQUE WRENCH

(Informative)

G.1 General

G.2 Calibration

G.3 Inspection

G.4 Action

G.5 Slip factor

 APPENDIX H PROVISIONS APPLYING TO NEW ZEALAND ONLY

(Normative)

H.1 Materials

American Society for Testing and Materials Standard

British Standards

European Committee for Standardization (CEN) Standards

Japanese Standards
H.2 Welding fabrication

R S S D

Description Normative requirements for Construction Category

CC1 CC2 CC3 CC4
1. Fabrication documentation

2. Sub-contracting
3. Materials

4. Structural steel products

5. Welding (Note 5)
 6. Welding inspection

7. Tolerances

NOTES:

1. Compliance of the abricator with all normative requirements of AS/NZS 1554.1 shall be verified by a
third party audit conducted by the Certification Body.
2. Full or partial traceability of the construction materials (steel, welding consumables etc.) shall be
maintained throughout the entire fabrication process as required.
 a. If partial traceability is required, the fabricator shall insure identification of all construction
materials used on the job through material test certificates.
b. If full traceability is required, the fabricator shall insure that each piece of steel used to
fabricate the section is traceable to the original material test certificate. Secondary attachments
as designated by the design engineer may require only partial traceability subject to agreement
between fabricator and design engineer.
3. The fabricator shall be certified by a third-party audit to AS/NZS ISO 3834 Part 2.
4. The minimum extent of non-destructive examination (NDE) shall be specified by the design engineer.
Guidance is given in NZS 3404.1:2009, Section 8.
5. The following shall be undertaken by the Design Engineer or his/her nominated representative before
prior to the start of welding:
a. The design engineer shall specify welding requirements in accordance with AS/NZS 1554 Part
1 to 7 as applicable. This includes weld category, weld size and extent of inspection [ref.
Clause 14.3.4, NZS 3404.1:1997]
b. All welding requirements shall be adequately reviewed by the design engineer, who on the
basis of experience or qualifications is competent to undertake the review. The extent of review
to be undertaken shall be nominated by the design engineer, taking into account those
materials and workmanship factors which are likely to influence the ability of the finished
construction to perform in the predicted manner [Ref. Clause 1.6.3.1NZS 3404.1:1997].
c. design engineer or by
his/her nominated representative who is competent to undertake the review prior to the start of
welding [Ref. Clause 1.6.3.2 Note (4) NZS 3404.1:1997 Part 1].
d. The extent of non-destructive examination (NDT) shall be nominated by the design engineer
who is competent in specifying NDT [Ref. Appendix D, Section D2, NZS 3404.1:1997]
6. Traceability of welders to individual welds shall be available either by documentation (e.g. weld plan) or
welder ID stamp for primary connection welds.
7. Documentation allowing traceability of welding procedures (WPS) to individual welds shall be available.
8. Competency of fabrication supervisor shall be verified through the professional interview .
Sub-contractors should comply with the same or higher Construction Category as the main contractor. It
is the responsibility of the main contractor to ensure that the sub-
according to the applicable Construction Category. This may require auditing of a sub-
premises.
9. NSR = No Specific Requirements