DIVISION 05 METALSMain Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dutai PART PART PART 14 12 13 14 15 16 17 24 22 23 34 32 33 34 35 36 37 SECTION 05 12.00 STRUCTURAL STEEL FRAMING GENERAL General Instructions Work Included Codes and Standards Inspection and Testing - General Acceptance of the Engineer Quality Assurance Related Work Specified Elsewhere PRODUCTS Materials Detail Design Fire Protection of Structural Steel Work EXECUTION Fabrication Inspection and Testing - Welds Erection Structural Stee! Decking Chamber and Deflections Cleaning Clear up Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200-1Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai SECTION 05 12.00 STRUCTURAL STEEL FRAMING PART 1 GENERAL 44 General instructions, 144 Works under this section shall be governed by Conditions of the Contract and Sections of Division 91 142 ‘The British Standards referred to in this Section are listed below together with any other references specified. The latest editions shall be used, including all current amendments and additions. 1.43 Any differences between the requirements of the BS and this Section shall be submitted to the Engireer for his ruling which shall be binding on the Contractor. 1414 The Contractor shall supply adequate plant, tools, service bolts, drifts, bolt tightening devices and other equipment to ensure that the steelwork is correctly erected in accordance with the relevant Codes and Standards. 12 Work Included 124 ‘This Specification covers the materials, detail design, fabrication and erection of structural steelwork in general as detailed on drawings, as specified and to the approval of the Engineer 122 ‘The design of steelwork shall be in accordance with BS 5950 Part | and BS 5400 ~ 3: 2000 unless otherwise specified 123 The execution of the work, including such design and detailing as may be required shall be performed in accordance with BS 5950 Perts | and 2 together with this specificaticn, Unless otnerwise specified, indicated on drawings or directed by the Engineer. 124 The material fabrication and erection of all structural stee! work shall confirm to the “National Structural Steel Work Specification for Building Construction” (UK) latest edition 13 Codes and Standards 134 ‘The British Standards referred to in this section are listed below, together with any other references specified. The latest editions shall be used, including all current amendments and additions. BS 4: Part 4 - Structural Stee! Sections: Specification for hot rolled sections BS 449: Part 2 ~The use of Structural Steel in Buildings: Metric units BS EN 22553:1995 & - Welding terms and symbols: Specification for symbols for BS EN 24063:1992 welding Khatib & Alami (CEC) Section 05 12.00 Structural Steel Framing 05 1200-2Main Works Contract Project No. DF1436 ‘Architectural, Structural and Civil Specifications. ‘The Address Residences Dubai Opera - Dubai BS EN 709:1983, BS EN 1043-1:1996 BS EN 1043-2:1997| BS EN 1320:1997 | - Methods of destructive testing fusion welded joints and weld BS EN 1321:1997 metal in steel BS EN 875:1995 BS EN 876: 1995 BS EN 895: 1995 BS EN 910:1996 BS EN 19162:2003 - Specification for cold rolled steel sections Bs 3692 - ISO Metric precision hexagon bolts, screws and nuts BS 3923Part2: Methods for ultrasonic examination of welds: Automatic examination of fusion welded butt joints in ferritic steels, BS 41902001 = ISO Metric black hexagon bolts, screws and nuts BS 4320 - Metal washers for general Engineering purposes BS EN 10026:1990 BS 7668:1994 BSEN 10029:1991, BS EN 10113-1:1993- pWeldable structural steels BS 10113-2:1993, BSEN 10113-3:19938 BSEN 10210:1994 BS EN 10056-1:99 Hot rolled structural steel sections Equal and unequal angles BS 4872 Part 1 - Approval testing of welders when welding procedure approval is not required Fusion welding of ste! Bs 4933 = ISO Metric black cup and countersunk head bolts and screws with hexagon nuts BS EN 12334:2001 - Process of arc welding of carbon and carbon manganese steels, BS 5531 - Code of Practice for safety in erecting structural frames BS 5950 - _ Structural use of steelwork in buildings Part 1 - Code of practice for design in simple and continuous construction: hot-rolled sections. Part 2: - Specification for materials, fabrication and erection: hot-rolled sections. BS EN 10160:99 Methods of testing & quality grading of ferritic steel plate by ultrasonic methods Bs 6037 - Permanently installed suspended access equipment. Bs 6072 ~ Method for magnetic particle flaw detection BS EN 287 ~ Approval of testing of welders for fusion welding, Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200-3Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai BS EN 238 Approval of welding procedures for metallic materials BS EN 440 Welding consumables. Wire electrodes and deposits of gas-shielded metal arc welding of non alloy and fire grain steels: Classification. BSEN 571-4 Non destructive tests. Penetrant testing BS EN 756 Weldable consumables wires, electrodes and wire fux ‘combinations for the submerged arc welding of carbon steel and medium tensile steel BS EN 970 Non destructive examination of fusion welds. Visual examination, BS EN 1435 Non-destructive examination of welded joints. Radiographic ‘examination of welded joints. BS EN 1714 Non destructive examination of welded joints. Acceptable levels. BS EN 10025 Hot rolled products of non-alloy structural steels and their delivery conditions BS EN 10028 Tolerances on dimensions, shape and mass for hot-rolled stee! plates 8mm thick or above. BS EN 10045 Charpy impact test on metallic materials, BS EN 10048 Hot rolled narrow steel strip. Tolerances on dimensions and shape. BS EN 10051 Continuously hot-rolled uncoated plate, sheet and strip of non-alloy and alloy steels - tolerances on dimensions and shape. BS EN 10219 Cold formed welded steel structural sections of non-alloy and fine grain steel BS EN 22653 Welding, brazed and soldered joints. Symbolic representation on drawings. BS EN 24063 Welding, brazing, soldering & braze welding of metas. 132 Other Reierences Nomenclature of process and reference numbers of symbolic representation on drawings. Euronorm 21 General technical delivery requirements for steel and iron and steel products Euronorin 164 Steel fiat products with specified through thickness properties. Technical conditions of delivery. National structural steelwork specification for building construction. (UK) Khatib & Alami (CEC) ‘Section 05 12 00 Structural Steel Framing 05 1200-4Main Works Contract Project No, DF1436 ‘Architectural, Structural and Civil Specifications The Address Residences Dubai Opera - Dubai 14 Inspection and Testing - General 144 The Contractor shall carry out all inspection and testing in accordance with this Section and the relevant standards, 142 In the evant that materials or workmanship fail to comply with the requirements specified herein, tre Contractor shall carry out further inspection and testing to satisfy the Engineer. Testing laboratories shall be to the approval of the Engineer. 143 The Contractor shall cary out any additional inspection and testing required by the Engineer at his own cost. 144 The Contractor shall demonstrate to the Engineer that full records are maintained through all stages of the work. Make these records freely available for inspection by the Engineer at any time. 15 Acceptance of the Engineer 154 Obtain asceptance of the Engineer wherever required, in writing before the work is undertaken. 182 If any deviation is required from any part of this Specification, obtain such approvals in writing before proceeding with any such deviation, 16 Quality Assurance 164 Operate own Quality Assurance System for all stages of the work and all work in accordanse with that system. Present suitable Quality Assurance accreditation to the Engineer. 162 Comply with the provisions of relevant Section of Division - 01 17 Related Work Specified Elsewhere Division c4 - General Requirements Section 033000 - Cast in Place Concrete Section 055000 - Metal Fabrications Section 07 8400 - Fire Stopping Section 039100 - Painting PART 2 PRODUCTS 24 Materials 244 Certification 21.1.1 Provide two copies of the manufacturer's test certificates verifying that the materials, comply with the relevant British Standard shall be provided by the Contractor to the Engineer forall structural steel, bolting materials, and welding consumables. 212 Storage 24.21 Store each grade of steel shall be stored separately and marked in accordance with the standards listed in Table 1 as appropriate 24.22 Clearly identity and store separately each type and grade of bolt and welding consumable. Khatib & Alami (CEC) Section 05 12 00 Structural Stee! Framing 05 1200-5Main Works Contract Project No. DF1436 Architectural, Structu'al and Civil Specifications, ‘The Address Residences Dubai Opera - Dubai 212.3 Store ech type of welding consumable in environmental conditions as recommended by the manafacturers, 2.4.3 ‘Specific Requirements, 2.1.3.1 Plates and Sections: 2.1.3.1.1. The dimensions of rolled steel sections shall comply with BS 4: Part | or BS EN 10056- 1:99. Dimensional tolerances shall comply with BS EN 10034 or BS EN 10056 as appropriated. The dimansional tolerances for flats round and square bars shall be as specified in BS EN 10025 Clause 2.2. The tolerances for plate and strip produced on continuous mills shall comply with BS EN 10051 or BS 1449 as appropriate, Tolerances for plates produced by non-con‘inuous mills shall comply with BS EN 10029, and thickness class A tolerances shall apply. The tolerance over or under the nominal thickness shall be equal to half the total thickness tolerance. 2.1.3.1.2 All steel in plates and sections shall comply with the standards listed in Table 1 as appropriate, except that rimming steel shall not be used. Only new steel shall be used; steel, which in the opinion of the Engineer is heavily pitted or badly rusted, shall not be used. 2.1.3.1.3 Except where noted or agreed otherwise, the particular grade of steel used shall be determired in accordance with BS 5950 Part | Section 2.4.4 and adopting a value of K ‘equal to one, 2.1.3.1.4 — Structural hollow sections shall be hot rolled structural hollow sections to BS EN 10210- 2:97 in steel to BS EN 10210 Part 1. Welded cold-formed steel structural hollow sections to BS EN 10219-2:97 shall not be substituted unless agreed to by the Engineer in writing. ‘Standard Product Type BS EN 10025: (1993) __| Hot rolled products of non-alloy structural steels = Technical delivery conditions. BS EN 10113 (1993) __| Hot rolled products in weldable fine grain structural steels. Parts 1,2 &3 Part 1 — General delivery conditions. Part 2 — Delivery conditions for normalised steels. BS 7613 (1994) Hot rolled quenched and tempered weldable structural steel plates BS EN 10210 (1994) | Hot finished structural hollow sections of non-aloy and Parts 1&2 fine grain structural steels Part 1 — Technical delivery requirements Part 2 — Dimensions, tolerances & sectional properties BS EN 10155 (1993) _| Structural steels with improved atmospheric corrosion resistance. Technical delivery conditions BS 7668 (1984) Weldable structural steels. Hot finished structural hollow section in weather resistant steels, ‘Table 4 Standards applicable to steel 243.2 Cold Rolled Sections: Cold rolled sections shall comply with BS EN 10162:2003, Khatib & Alami (CEC) Section 05 1200 Structural Steel Framing 05 1200-6Main Works Contract Project No, DF1436 Architectural, Structural and Civil Specifications The Address Residences Dubai Opera - Dubai 213.3 21.34 21.36 2136 Electrodas: All electiodes shall have a yield strength, tensile strength, toughness and ductility not less than those specified for the grade of steel being welded, Covered electrodes for manual metal-arc welding shall comply with the requirements of BS EN 499:1995. ‘When weathering steel is to be welded the welding electrodes shall be of matching composition to the parent material Bolts, Nuts and Washers Ordinary bolts and nuts shall comply with BS 3692, BS 4190 or BS 4395 Part | for hexagon headed bolts or BS 4933 for cup headed or countersunk bolts. Unless otherwise specified bolts and nuts shall be of grade 8.8 Ordinary washers shall comply with BS 4320. Plain washers shall be made of steel! and taper or other special shaped washers shall be of steel or malleable cast iron. Bolting materials that have been sheradised or otherwise coated shall be manufactured and coated to give a satisfactory ft between the finished bolt and its nut. High strength friction grip bolts, nuts and washers shall comply with BS 4395 Part 1. Galvanising, sherardising, or electroplating of nuts, bolts and washers shall be carried out only by the manufacturer. Substitution If it is found necessary to substitute alternative sections for any of the steel sections specified, the Contractor shall provide complete details of the proposed substitutions including drawing showing the substitution, for the approval of the Engineer in writing for the subslitution before commencing any fabrication Lamination Testing Except in the case of special plate with through thickness properties guaranteed by the manufaciurer, all plates and sections 40mm or over in thickness shall be ultrasonically tested for laminations, and shall meet the requirements for level B6 of BS 5996, Other pletes may be specified to be ultrasonically tested for laminations. Unless otherwise specified they shall meet the requirements of level B6 of BS EN 10160:99, Welded joints that cause high tensile through thickness strains to occur (as discussed in Appendix G of BS 5135), shall be fabricated from steel that meets the quality level 225 of BS EN 10164 For all steel plates and sections which will be subject to through-thickness stresses, the Contractor shall carry out non-destructive testing on the steel to ensure that the affected zones af® free from laminations and inclusions, Table 18 of BS EN 12334:2001 shall be used to determine acceptance levels for steel products, the particular quality category required shall as directed by the Engineer. Khatib & Alami (CEC) ‘Section 05 12.00, Structural Stee! Framing 05 1200-7Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications. ‘The Address Residences Dubai Opera - Dubai 22 224 222 22.22 22.23 2224 22.25 223 2.23.4 Detail Design Drawings and documents The Engineer will supply the Contractor with information necessary for the preparation of hhis drawngs and documents. If the Contractor discovers any contradiction or ambiguity in the information supplied, written clarification shall be obtained from the Engineer. ‘The Contractor shall provide the following documents, ~ matking plans and details for holding-down bolts and other embedded items = fabrication drawings = conrection details including calculations - welding procedure details - fabrication method statement = erection marking plans = erection method statement including calculations ~ details of the Q.A. plan for structural steelwork together with full details of the inspection documents. Two copies of each document shall be submitted to the Engineer for approval. Fabrication shall not be commenced until such approval has been obtained from the Engineer. The drawings shall be submitted in related batches sufficiently in advance of the scheduled fabrication date to ensure that the Engineer has sufficient time and information to give full consideration to the proposals on the documents and for any changes to be incorporated and re-submitted for approval. Unless otherwise specified or agreed in writing, a period of at least three weeks shall be allowed from receipt of the documents from the Engineer. ‘These approved drawings shall form part of the Contract. The Contractor shall check and certify all documents before submitting them for the approval of the Engineer. The Engineer will verity the correct interpretation of his requirements but shall not be responsisle for verifying the dimensions or checking the strength or practicality of the details. Approval accorded by the Engineer shall not relieve the Contractor of is obligations. The Contractor shall be entirely responsible for his drawings including their accuracy (relative to the Contract drawings), the correctness of details, and the proper design of Connections and joints, and for any additional work required as a result of defects in his drawings, Where the steelwork is to be connected to any existing structure, the Contractor shall verify all dimensions that may affect fabrication and notify the Engineer in writing of any discrepancies before fabrication commences. Connections and Joints General The Contractor shall design the connections where the drawings indicate the loads on members at connections but do not detail the connections, All other connections shall be as indicated / detailed on the drawings. All connections designed by the Contractor shall be subject to the approval of the Engineer. The Contractor shall provide calculations to demonstrate the adequacy of Khatib & Alami (CEC) Section 05 12.00 Structural Steel Framing 05 1200-8Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai connections, which are designed by him. Connectons shall be designed taking into account the effects of any eccentricity on the component parts of the connection, including welds and bolt. ‘The Contractor shall not introduce eccentricity into the layout of the members nor into the arrangement of the connections except as agreed by the Engineer in writing Before commencement of workshop drawings the Contractor shall prepare and submit typical details proposed for the connections, for the approval of the Engineer. ‘The Engineer shall require at least one week after these drawings have been submitted by the Contractor for his review, after which the Contractor shall be called upon to discuss these drawings and co-ordinate the procedures before approval. ‘Simply supported end connections shall provide sufficient flexibility to accommodate the fend rotation of the beam. This flexibility may be provided by movement of bolts in clearance holes or by flexure of cleats or endplates. Care must be taken to ensure that the welds and bolts are strong enough to resist the forces necessary to produce such movement or flexure. In cleated end connections of beams the cleats shall project 2mm beyond the end of the member unless otherwise shown on drawings. Load bearing connections shall have not less than two bolts of a size appropriate to the member or else welds else welds giving a similar capacity will be provided. 2.23.2 Welded Connections 2.23.21 In addition to meeting the requirements of BS 5950 Part 1, for the design of welds, the guidance given in BS EN 1011-1:98 and BSEN 1011-2:2001 shall be applied 223.22 The dimensions of all welds shall be clearly specified on the working drawings using symbols in accordance with BS 499, Part 2 224 Bolted Connections Preloaded high strength friction grip bolts shall only be used when specified on the Engineer's drawings or when previously agreed by the Engineer. Unless specified otherwise, ordinary bolts in clearance holes will be acceptable for connections of such members as wind bracings, sheeting rails and purlins and for beam end cleats. Nuts in connections subject to vibration shall be of the self-locking type or provided with lock-nuts, except where high strength friction grip fasteners are used. ‘Whenever bolted connections are used, the reduced sectional area of members shall be ‘computed and the members strengthened if required 2.3 Fire Protection of Structural Steel Work 234 ‘Scope The fire protection works comprise the encasement of primary structural steelwork in fire rated areas as detailed on drawings, as specified herein and to the approval of the Enginee’, Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200-9Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications The Address Residences Dubai Opera - Dubai Spray applied proprietary application for all other steel work, which are generally concealed by subsequent fixing of metal cladding or suspended ceilings or fire protection boards. 232 General Related British/ASTM Standards and other References:- BS476: Fire Tests on Building Materials & Structures, : Part ASTM E84 — Method of Test for Fire Propagation for Products Part TIASTM E84 Surface spread of flame Tests for Materials Part 1 1/ASTM E1354 Method of assessing the heat emission from Materials Part 21 Method’ for determination of the fire resistance of Icad bearing elements of Construction. ASFP Fire Protection to Structural Steel in Buildings - 4" Edition or later 233 GUARANTEE & WARRANTY The Manufacturer and the installer will provide all relevant guarantees end warranties relating to the materials and workmanship for the fire protection of the structural steelwork. Minimum warrantee period shall be Ten (10) years, 234 Qualifications The installation and or application of the steelwork fire protection, shall be carried out only by an Installer or Applicator, recognized by the fire protection material Manufacturer, as having the requisite technical skills and experience Applicatons of spray coating to be carried out in accordance with BS 8202-1 ‘The Cortractor shall submit documentary evidence in support of this for the approval of the Engineer. 235 ‘Samples A sample areas of Spray Fire Resistive Materials (SFRM) shall be applied to structural steelwork to an extent and location as directed by the Engineer, which, when approved, shall be retained for Quality Control purposes, until directed otherwise by the Engineer. 2.36. Materials 2.3.6.1 Spray Fire Resistive Material (SERM) 2.3.6.1.1 SERM FP-01: INTERIOR CONCEALED STEEL Spray fire protection material shall be Manufacturer's standard product; factory- mixed, dry formulation of gypsum or Portland cement binders, additives, and lightweight mineral or synthetic aggregates mixed with water at project site to form a slurry ot mortar for conveyance and application, to the requisite predetermined thicknesses, to the structural steelwork Physical Properties: Spray applied fire protection material FP-01 shall have the minimum values to achieve designated fire-resistance ratings, measured per standard test methods referenced with each property as follows: Khatib & Alami (CEC) Section 05 712 00 Structural Steel Framing 05 1200-10Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications The Address Residences Dubai Opera - Dutai 2.36.1.2 a) Density: Not less than 240 kg/cub met as measured per ASTM E605. b) Thickness: As required on the project and as tabulated for the selected SFRM product in ASFP Fire Protection to Structural Steel in Buildings - 4" Edition or later. ©) Bond Strength: Minimum 7.2 kPa cohesive-adhesive strength based on field testing according to ASTM E736, 4) Compressive Strength: Minimum 69 kPa according to ASTM E761 €) Corrosion Resistance: No evidence of corrosion according to ASTM E937 1) Deflection: No cracking, spalling, or delamination according to ASTM E759. 4) Effect of Impact on Bonding: No cracking, spalling, or delamination according to ASTM E760. h) Air Erosion: Maximum weight loss of 0.270 gm/sq.m. in 24-hours according to ‘ASTM E859. i) Surface Burning Characteristics: Comply with ASTM E84; i. Flame Spread Index: 10 or less ii, Smoke-Developed Index: 0 SFRM FP-02: Steel which is susceptible to mechani 9 exterior Spray fire protection material shall be Manufacturer's standard product; factory- mixed, dry, cement aggregate formulation of Portland cement binders, additives, and inorganic aggregates mixed with water at project site to form a slurry or mortar for conveyance and application, to the requisite predetermined thicknesses, to the structural steelwork. Physical Properties: Spray applied fire protection material FP-02 shall have the minimum values to achieve designated fire-resistance ratings, measured per standard test methods referenced with each property as follows: a) Density: Not less than 640 kg/cub met as measured per ASTM E605, b) Thickness: As required on the project and as tabulated for the selected SFRM product in ASFP Fire Protection to Structural Stee! in Buildings - 4" Edition or later. c) Bond Strength: Minimum 48 kPa cohesive-adhesive strength based on field testing according to ASTM E736. d) Compressive Strength: Minimum 2068 kPa according to ASTM E761 ) Corrosion Resistance: No evidence of corrosion according to ASTM E937, f) Deflection: No cracking, spalling, or delamination according to ASTM E759. 9) Effect of Impact on Bonding: No cracking, spalling, or delamination according to ASTM E760. h) Air Erosion: Maximum weight loss of 0.270 gmisq.m. in 24-hours according to ASTM E859. i) Surface Burning Characteristics: Comply with ASTM E84; Khatib & Alami (CEC) Section 05 12 00 Structural Stee! Framing 05 1200-11Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai 236.2 237 23.74 23.7.2 237.3 Flame Spread Index: 10 or less ‘Smoke-Developed Index: 0 Material Storage & Handling Materials shall be stored strictly in accordance with the Manufacturer's written storage recommendations, particularly when wet, hot and humid conditions are applicable. WORKMANSHIP (Preparation & Application) The substrate shall comprise factory primed steelwork. The primer shall be two-pack zinc rich Epoxy Non-Alkyd based coating or a two-pack epoxy zinc phosphate. Total DFT of the primer shall be limited to 100 microns. Manufacturer will confirm compatibility of primer with its proposed material For spray applied fire protection coatings the substrate shail be clean, dry and free from dust, and oil or any condition likely to prevent good adhesion, after all damages to primer coat has been made good. Spray Applied Fire Resistive Coating (SFRM) shall be applied to the factory primed steelwork strictly in accordance with the Manufacturer's written application instructions, as specified herein or as indicated on drawings and to the approval of the Engineer SFRM shall only be applied when the substrate or air temperature is above 4°C and rising; not more than 45°C and, at least 2°C above the dew point temperature. Ventilation: Ventilate building spaces during and after application of fireproofing, providing complete air exchanges according to manufacturer's written instructions. Use natural means or, if they are inadequate, forced-air circulation until fireproofing dries thoroughly. The thickness of the Material Coating shall be determined in accordance with the manufacturer's recommendations and as listed in ASFP Fire Protection to Structural Stee! in Buildings — 4" Edition or later, from the Hp/A section factors based upon the size & profile; degree of exposure and actual location of each structural steelwork member. The compkted coating shall be protected from physical damage, by approved means, until handover. TESTING The testing of applied fire protection materials shall be in accordance with BS476/ASTM standards as referred to in Section 2.3.2 of this specification, The installer/Applicator shall submit to the Engineer, all fire protection material Manufacturers’ Product Technical Data and independent Fire Test Assessments, ‘or Approval, before any orders for materials are placed along with method statement Tests for Dry Density, Thickness and Bond Strength shall be conducted at site for field applied SFRM in accordance with AWC! Technical Manual 12-A. These tests will be carried out by the SFRM applicator in presence of Engineer's representative and Manufacturer's representative results of which will be recorded and submitted to the Engineer. Any deficient areas shall be highlighted and remedial steps taken for the rectification of the same, to the satisfaction of the Engineer. Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200 - 12‘Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dutai PART 313 3434 344 3144 314.2 3.1.4.3 314.4 314.5 3146 345 3.1.5.1 3 EXECUTION Fabrication General Any material identification marks, which have been hard stamped into the material shall be cut off in the course of fabrication. Measurement All measurement shall be made by a steel tape, which has been certified to be correct at 20°C. The tape shall be at the same temperature of the steel to be measured and proper precautions shall be taken to tension the tape correctly Straightening All plates, bars and sections shall be flat, straight and free from twist within the tolerances specified in the relevant British Standards, unless more stringent tolerances are specified on the drawings. Any flattening or straightening required to achieve the required tolerances or to satisfy fit up requirements shall be carried out before any other operation is performed on them. The method adopted for such work shall not to deface or weaken the mateial Cutting and Machining Steel may be sawn, sheared, cropped or machine flame cut. Where it is impractical to use machine flame cutting, the use of hand flame cutting may be permitted subject to the ‘approval of the Engineer. If hand flame cutting is used, dressing or other treatment of the ‘cut edges, depending on the details ofthe joint or member will be provided ‘Where notches are necessary they shall have smooth radiused internal comers, produced by drilling holes not less than 20mm diameter before cutting the rest of the notch or by carefully controlled flame cutting All burrs left by sawing, cropping or shearing shall be removed before fabrication or assembly. All sharp arises shall be removed by light grinding, ‘The Contractor shall inform the Engineer of members on which he will be using shearing or flame cutting and in cases where steel so cut is specified as being subject to dynamic Or fatigue loading or liable to brittle fracture, the sheared or flame cut edges shall be machined to a depth to be agreed by the Engineer. The ends of compression members at splices, caps or bases, dependent on contact for the transmission of compressive stress, shall be prepared so that the butting faces are in contact aver at least 60% of the bearing area except for small clearances not exceeding 0.25 mm. Over the remaining area the gap shall not exceed 0.50 mm. Base and cap plates and other bearing surfaces shall also be prepared to the same standard. Members shall be adequately supported in both the vertical and horizontal planes during cutting 0 machining to ensure that the prepared ends are square to the axis of the member, Eiltted Pletes and Stiffeners The ends of fitted plates and stiffeners shall be accurately sawn or sheared and ground to fit tightly vetween the flanges or parts to be stiffened. The maximum gap shall not exceed 0.25 mr. Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200-13‘Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai 316 ‘Smithed Work 3.1.6.1 All forging shall be performed in such a manner as not to impair the strength of the metal ‘The metal shall not be worked after it has fallen to a ‘blue heat. 347 Holes 3.1.7.4. Holing shall be in accordance with BS 5950 Pert 2. All burrs and rags shall be removed. 3.4.7.2 Slotted holes shail either be punched in one operation or else formed by punching or drilling two round holes and completed by high quality flame cutting and dressing, to ensure that the bolt can travel the full length of the slot freely. 3.1.7.3 Gircular holes for bolts shail not be flame cut 348 Welding 3.1.8.1 Welding shell comply with the requirements and recommendations of BSEN 1011-1:98 & BS EN 1011-2:2001 except as otherwise indicated on Drawings or specified. 3.1.8.2 The Contractor shall determine the welding procedure to meet the requirements of this, specification. 3.1.83 Unless otherwise specified, T-butt welds shall be reinforced by equal-leg filet welds of leg length ecual to a quarter of the thickness of the thinner plate joined, but not less than 3mm nor greater than 10 mm. 3.1.8.4 Where the steelwork is to be blasted and metal sprayed or galvanised after fabrication, cleats and other solid attachments welded to the member shall be welded all round to seal the unprotected surface. 3.1.8.5 Welding orocedures not complying with BS EN 10025, BS EN 10113, BS EN 10155 or 8S EN 10210 - Grades $275 & S356 shall be agreed with the Engineer before fabrication is, started, on the basis of weld procedure tests in accordance with BS EN 288, 3.1.8.6 Except as otherwise specified, the fitup of elements before welding shall be in accordarce with the recommendations of clause 11.1 of BS §135 for manual welding 3.1.8.7 The root edges or root faces of butt welds shall not be out of alignment by more than 15 percent of the thickness of the thinner material but not greater than mm 3.1.8.8 The Contractor shall demonstrate to the satisfaction of the Engineer that the proposed weld procedure details are derived from procedures which have already been approved, ‘Where weld procedure tests are required to be performed, the tests shall be in accordarce with BS EN 288, 3.1.8.9 All welders shall be suitably qualified and experienced for the work on which they ere ‘employed. Welders shail be tested to meet the requirements of BS EN 287 Part 1 or BS 4872 part 1 as appropriate. Welder testing shall be witnessed and certificates endorsed by an independent UAE Inspection Authority 3.1.8.10 The certification shall remain valid providing it complies with the conditions for re-approval of certification specified in BS EN 287 Part 1 3.1.8.1 The Contractor shall keep records identifying the welder for each welded joint Khatib & Alami (CEC) Section 05 12 00 Structural Steel Framing 05 1200-14Main Works Contract Project No. DF 1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai 3.18.12 Welded attachments for fabrication or erection purposes shall be subject to the Engineer's approval and shall be clearly shown on the fabrication drawings. 319 Bolted Connections 3.1.9.1 Bolting up with Glose Tolerance Bolts Holes for close tolerance bolts shalll be drilled and reamed. Where the holes are not drilled through the total thicknesses in one operation, the parts to be joined together shall be accurately lined up with parallel drifts of a diameter not greater than the nominal size of the hole and not smaller than 0.15 mm less than the nominal diameter and the holes then be reamed. A close tolerance bolt shall be fitted in each hole reamed and tightened before the next nole is reamed, All bolts shall be re-tightened after the last bolt has been fitted. 3.1.10 Bolted Movement Connections 3.1.10.1 Slotted Foles for movement connections shall be provided with shouldered bolts, spring washers to the approval of the Engineer or as detailed on drawings. att rrecting hol a 3.1.11.1 Drifting to align holes shall not enlarge the holes or distort the metal, Holes which cannot be aligned without distortion shall be a cause for rejection unless enlargement by reaming is specifically approved by the Engineer. 3.1.12 Provision of Washers 3112.1 Washers shall be provided at slotted holes and elsewhere as specified. With metal sprayed steelwork @ washer shall always be provided under both head and nut 3112.2 Square taper washers shall be provided for all bolts where the bolt head or nut is bearing on a surface at an angle greater than 93° or less than 87° to the bolt axis. 3.1.13 Botting Wetal Sprayed or Galvanised Steelwork: 3.1.13.1 Ordinary bolted connections on metal sprayed or galvanised steelwork shall be made using spun galvanised or sherardised bolts, nuts and washers except where connecting coated steelwork to black steelwork. 3.4.44 Marking 3.1.4.1 Each piese of steel shall be uniquely identified throughout the fabrication process. Each piece of steel shall be distinctly marked before despatch in accordance with the marking drawing prepared by the Steelwork Contractor. Where applicable further markings system shall be used to assist erection at site, by showing from which works it has come and to which crene or area itis to be delivered. 3.1.14.2 The location of marks on members shall be consistent and shall be such that the marks are clearly visible both before and after erection. 3.1143 Painted marks shall be applied using a paint that is compatible both chemically and in colour wih the final site anti-corrosion treatment. 3.1.14.4 The method of marking steelwork which is to be supplied to site fully painted shall, unless specified otherwise, be as agreed with the Engineer. iKhatib & Alami (CEC) Section 05 12.00 Structural Steel Framing 05 1200-15Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications. The Address Residences Dubai Opera - Dubai 3.1.14.5 34.15 31.15.41 3.1.18.2 3.1.18. 3.1.15.4 31.15.58 3.1.15.6 32 324 3.22 3.23 324 325 3.26 The painting of the Contractor's name or other advertising matter on steelwork is not permitted. Any such advertisement must be in the form of labels which are to be removed after the steel arrives on site. Surfaces ‘Any minor surface defects such as surface laminations, blow holes and crevices exposed by blast cleaning shall, subject to the approval of the Engineer, be made good as specified in BS EN 10025, BS EN 10113, BS EN 10165, BS EN 10210, BS 7613 or BS 7668 as appropriate. Any major surface defects shall be reported to the Engineer and shall be treated as directed, ‘Surfaces which become inaccessible after fabrication or assembly, such as the inside of structural hollow sections and other box sections, shall be sealed off from the outside atmosphere by continuous welds unless specified otherwise. Hollow embers, which are to be galvanised shall have vent holes. These shall be large enough to ensure internal galvanising or if so specified shall be sealed after the member has been galvanised. Contact surfaces, shall be treated as specified under Corrosion Protection in Section 09 91 00, Where specified on the drawing machined surfaces shall receive an approved coat of travel vamish within four hours of machining. Inspection and Testing - Welds ‘The Contractor shall carry out inspection and testing of welding to meet the requirements and recommendations of BS 5135, unless otherwise indicated on the Contract Drawings or specified elsewhere. Welds shall be inspected and tested in accordance with tables 1, 2, 3 & 4 below. Testing producers shall be in accordance with BS EN 1435, BS 3923, BSEN 1714 or equal and approved. All welds shall have 100 percent visual inspection to BS EN 970:1997, in addition to the requirements of this specification and the drawings. Inspection and testing by the Contractor shall be carried out by suitably qualified and ‘experienced staff to the approval of the Engineer and all in accordance with the relevent BS listed in Sub-Section 1.3. Testing shall be carried out by an independent and accredited UAE laboratory. ‘The Contractor shall provide every facility to the Engineer or such inspector or testing agencies as he may appoint to visit at all reasonable times all places where work is carried out and to inspect and test the steelwork during all stages of preparation, fabrication and trial assembly. When trial assembly is specified it shall be carried out in the Contractor's works to the extent required by the Engineer to prove the accuracy of the workmanship. When parts, which have to fit together are manufactured in different works or for any reason cannot be matched before dispatch to the site, the Contractor shall make adequate provision to ensure a correct fit by providing checking jigs or other suitable means satisfactory to the Engineer, Khatib & Alami (CEC) Seation 05 12 00 ‘Structural Steel Framing 05 1200-16Main Works Contract Project No. DF1436 ‘Architectural, Structural and Civil Specifications The Address Residences Dubai Opera - Dubai 327 The Contractor before making any trial assembly shall give a minimum of 5 working days advance notice to the Engineer of his intention. 328 ‘When random (less than 100 percent) volumetric non-destructive testing of welds is specified, it shall be ensured that the positions tested are fully representative of all aspects of the welding, 329 ‘The paticular method of non-destructive weld testing, selected by the Contractor, shall be sufficiently sensitive to allow the proper detection of defects and interpretation of results appropriate to the quality category. 3.2.10 When random (less than 100 percent) volumetric non-destructive testing of welds reveals, unacceptable defects in a joint, all previously untested joints in the group represented shall be tested until it is established to the satisfaction of the Engineer that the cause of the defects has been demonstrated and the defects eliminated. This may require 100 percent testing 3.2.11 Any work, which does not comply with the requirements of this specification shall be rectified promptly to the satisfaction of the Engineer including any further inspection and testing which he requires. 3.2.12 Inspection by the Engineer shall not relieve the Contractor of his responsibilty to perform his own quaiity control operations to ensure that all work meets the specification nor of his responsibility to rectify all defects including any which appear or are found subsequently Quality Location of Weld Category Class A__| All main column elements: All Belt truss and Outrigger elements including end connections. AAll Pyramidical crown elements. End plates or flanges and associated butt welds or fillet welds within ‘connections subject to through thickness tension, where the plate thickness or weld size is greater than 25 mm, Butt welds which are subject to tensile stresses on all material with thickness greater than 30 mm. Class B__| All other elements other than those shown in Class C. Class C | Spiral stairs or ladders Miscellaneous steel supports Table 1, Requirements for Inspection & Testing Of Welds (& Stee! Products at Zones Subject to ‘Through Thickness Stresses) in accordance with BS 5135: Appendix H Tables 18 & 19, Weld Category Requirements Normal — all welds uniess _ | The weld shall not be undersize. Butt welds shall have a uniform otherwise stated below | convexity up to a maximum of weld size 5 or 3 mm whichever is the lesser. Concave fillet welds shall have a throat thickness not less than 0.7 times the specified leg length. Convex fillet welds shall have a throat thickness not more than 0.9 times the actual leg __| tength. All welds shall have a smooth surface ‘Special — All welds on The above requirements apply. In addition, all welds shall be steelwork which is not clad_| ground smooth. Table 2: Particular Reauirements for Welds Profile & surface Finish Khatib & Alami (CEC) Section 05 1200 Structural Stee! Framing 05 1200-17Main Works Contract Project No. DF1436 Architectural, Structural and Civil Specifications ‘The Address Residences Dubai Opera - Dubai Weld Category Requirements ‘All Main columns, Bell trusses, Outrigger members, paramedical Comply with BS5400 Part 10 crown elements and connections Table 3: Parti nits for Fatigue Resistance of Weldments Weld Category Requirements ‘AllMain columns, Beit truss, Carry out weld procedure test for each weld detail or Outrigger members, paramedical provide certified weld procedure details as an crown elements and connections alternative Table 4: Particular Requirements for Weld Procedure Tests in accordance with BS EN 268 3.3 Erection 334 Method of Erection 3.3.1.1 The Contractor shall submit a detailed Method Statement for the approval of the Engineer before erection. Where required and called for erection drawings shall be prepared and submitted to the Engineer for approval. 3.3.1.2 Erection of the steelwork shall be carried out in a safe manner and in accordance with the concerned Authorities regulations and requirements. 3.3.1.3 The work shall be arranged in such as manner as to facilitate phased handover of the steelwork for subsequent operations and in particular for the stage wise handing over as detailed in Sections of Divisions - 01. 33.2 ‘Transport, Storage, Handling and Attachments 3.32.1 Care shell be taken when transporting, storing, handling or erecting all material to ensure that no part is damaged. Damage to any part of the structure either before or during erection shall be immediately brought to the notice of the Engineer. Damaged material shall be rectified or replaced. No part that is damaged shall be assembled into the structure. Damaged and subsequently rectified parts shall not be assembled without the written approval of the Engineer. 3.32.2 —— Steelwork shall be stored on dunnage avoiding contact with the ground and avoiding any water contact or retention 3.32.3 Particular care shall be taken when transporting, handling or storing parts, which have been metal sprayed, galvanised or painted. If this coating is damaged it shall be restored to comply with the relevant requirements of Corrosion Protection. 3.32.4 Lifting points shall be suitably wrapped and protected and steel slings shall not be allowed to come into direct contact with coated steelwork. 332.5 Welded attachments shall not be employed unless they are clearly shown on the fabrication drawings. Khatib & Alami (CEC) ‘Section 05 12 00 Structural Steel Framing 05 1200-18