ENGINEERING OFFICE

GENERAL SPECIFICATIONS DIVISION 5 - METALS

SECTION 05120 - STRUCTURAL STEEL

PART 1 - GENERAL

1.1 STANDARDS

A. The standards referred to in this section are:

TABLE: 05120-1A
BS 4 Structural steel sections
Part 1 Hot rolled sections
BS 449 Part 2 The use of structural steel in building
BS 639 Covered electrodes for the manual metal-arc welding of carbon and carbon
manganese steels
BS 729 Hot dip galvanised coatings on iron and steel articles
BS 2853 Design and testing of steel overhead runway beams and travelling trolleys
BS 3416 Black bitumen coating solutions for cold application
BS 3692} ISO metric precision Hexagon bolts, screw & nuts.
BS 3693}
BS 4190 ISO metric black hexagon bolts, screws and nuts.
BS 4320 Metal washers for general engineering purposes
BS EN 10025 Hot rolled products of Non-Alloy Structural steels
BS 4395 High strength friction grip bolts and associated nuts and washers for structural
engineering:
Part 1 General grade
Part 2 Higher grade bolts and nuts and general grade washers
BS 4606 The use of high strength friction grip bolts in structural steelwork
BS 4848 Hot rolled structural steel sections
Part 2 Hollows sections
Part 4 Equal and unequal angles
BS 4872 Approval testing of welders
Part 1 Fusion welding of steel
BS 4933 ISO metric black cup and countersunk head bolts and screws with hexagon nuts
BS 5135 Metal-arc welding of carbon and carbon manganese steels
BS 5493 Code of Practice for protective coating of iron and steel structures against corrosion
BS 5950 Structural use of steelwork in building.
BS EN10210-1 Hot finished structural hollow sections of non-alloy and fine grained structural
steels-part 1

1.2 SCOPE OF WORK

A. The extent of structural steelwork is shown on the drawings, which show size and location of
members, typical connections, and type of steel required.

B. Structural steel is that work defined in BS 5950 "Structural use of steel work in building".

C. All steelwork including connections and other details not given in the contract documentation
shall be designed and fabricated to comply with BS 449, Part 2.

1.3 QUALITY ASSURANCE

A. Field testing and inspection of steel work will be performed by an independent laboratory
approved by the EO. The contractor shall provide the laboratory inspector with free access to
all places where materials or components are stored or fabricated and in their erected
position. The contractor shall notify the laboratory in sufficient time prior to fabrication or
erection work to allow testing and inspection without delaying the work.

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B. All work shall be performed by qualified operators experienced in their field of work as
required under this section.

C. Design of structural parts to be under the direct supervision of a professional engineer

experienced in the design of such components and shall confirm to the applicable industrial
standards.

D. Tolerances:
1. Maintain tolerances confirming to AISC code of standard practice.
2. Permissible variation tolerances confirming to ASTM A6/A6m.

E. Torque wrench calibration:

1. Check calibration device for setting calibrated torque wrenches for accuracy not more
than thirty (30) days prior to use on project and at intervals not more than six months
thereafter.
2. Provide torque wrench calibration as specified in AISC specification for structural joints.

F. Welding qualification and certification:

G. Furnish written welding procedure for all welds.

1. Each welder, tacker, and welding operator shall be certified by test within the past six
months to perform type of work required in conformance with AWS structural welding
code.
2. Maintain duplicate qualification and certification records at the job site readily available
for examination of test results.

H. Galvanize:

1. Reject all galvanized steel not confirming to specifications.

1.4 SUBMITTALS

A. Shop Drawings: Submit the following in accordance with section 01330 Submittal
Procedures:

1. Submit shop drawings for review by EO Engineer prior to fabrication.

2. Submit complete and checked shop drawings for all structural steel components. Show
materials, anchor bolts, members and connection details, piece marks, openings, shop
and field bolting and welding. Indicate cleaning and shop painting requirements.
3. Submit, prior to welding, the welding procedure for each type of weld.
4. Submit qualification test reports bearing witness certification of an independent
accredited testing laboratory for each welder, welding operator and tacker employed in
work.

B. Shop drawings detailing fabrication of structural steel components:

1. Include details of cuts, connections, splices, camber, holes and other pertinent data.
2. Indicate welds by standard AWS symbols, distinguishing between shop and field welds
and show size, length and type of each weld.
3. Indicate type, size and length of bolts distinguishing between shop and field bolts.
Identify high strength bolted slip-critical, direct tension or tensioned shear/bearing
connections.
4. Include shop drawings signed and sealed by a qualified professional engineer
responsible for their preparation.
5. Methods of erection and calculation of erection stresses.
6. Methods of bracing and temporary guys.
7. Provide setting drawings, templates and directions for installation of anchor bolts and
other anchorage to be installed as work of other section.

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C. Qualification data for firms and persons specified in the ‘Quality Assurance’ article to
demonstrate their capabilities and experience. Include lists of completed projects with project
names and addresses, names and addresses of architects/engineers and owners and other
information specified.

D. Product Data: Submit producers or manufacturer’s specifications and installation instructions.

Include mill test reports in accordance with ASTM-A6, laboratory test reports and other data
to show compliance with specifications (including specified standards) for the following
products.

1. Structural steel (each type), including certified copies of mill reports covering physical
and chemical properties.
2. Bolts, nuts, and washers including mechanical properties and chemical analysis.
3. Direct tension indicators
4. Shear stud connectors.
5. Shop primers
6. Non-shrink grout
7. Welding electrodes.

E. Submit mill certificates and certified copy of reports for all analyses and tests required by
referenced ASTM specifications and AWS structural welding code.

F. Fabricator and Erector: Submit the name of the proposed fabricator and erector with
reference of work of a similar nature carried out by him on other projects, with relevant dates.

G. Submit certificate of compliance that surface preparation and painting conforms to the
specifications.

1. Provide list of coating products proposed by type, brand and manufacturer.

2. Provide paint manufacturer’s current printed recommendations and product data sheets
for each product used.
3. Provide shop painting applicator’s correspondence for determining compatibility of shop
coatings with field coats and for selecting manufacturer’ producing field coats.

H. Submit materials information and data for EO Engineer review at least twenty-one (21)
calendar days prior to scheduled start date of any fabrication.

I. Test reports conducted on shop and field-bolted and welded connections. Include data on
type(s) of tests conducted and test results. State compliance or non-compliance with
specifications.

J. Submit certificate of compliance with ASTM Specifications for zinc-coatings.

K. Submit certified copies of each survey conducted by a licensed Land Surveyor, showing
elevations and locations of base plates and anchor bolts to receive structural steel and final
elevations and for major members. Indicate discrepancies between actual installation and
contract documents.

L. No fabrication work is to commence before approval of rest reports and submittals.

M. Submit field inspections and test report performed by independent testing and inspection
agency at various stages of steel structural work.

N. Method statement: Submit for approval, Quality control method statement in accordance with
quality assurance procedures, and erection method statement.

1.5 SHOP DRAWINGS AND MARKING OF STEEL WORK

A. The Contractor shall submit to the Engineer in accordance with section 01330 "Submitting
Procedures" setting out plans, shop drawings, connection details, material lists and
calculation sheets confirming that the structural steelwork connections will withstand the

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imposed forces and moments and shall make amendments to such plans, drawings, details,
lists and calculations as may be required by the Engineer.

B. On receipt of the Engineer's agreement to such plans, drawings and lists, the Contractor shall
submit further copies of each to the Engineer. Fabrication shall not be started until the
Engineer has agreed to the relevant plans, drawings, details, lists and calculations and once
such agreement has been given, no alterations shall be made to such plans, drawings,
details, lists and calculations without the further agreement of the Engineer. The Contractor
shall submit all drawings and documents in a sequence and at times compatible with the
program of work.

C. The design shall be in accordance with BS 5950 and other relevant British Standards.

D. The Contractor shall take all necessary site dimensions to ensure that the correct detailing,
fabrication and erection is carried out.

E. The agreement of the Engineer as described in clause 1.5 shall not relieve the Contractor of
his responsibility for the sufficiency of the calculations, drawings, etc. or for the correct
fabrication, assembly and erection of the permanent works.

F. Before dispatch from the workshop, all steelwork shall be clearly and indelibly marked to
indicate its position and direction in the Permanent Works, the grade of steel used for
fabrication and the weight of each piece if this exceeds one tonne. Such markings shall
correspond with those shown on the shop drawings.

G. On completion of steelwork erection, the Contractor shall supply to the Engineer two
reproducible transparencies of all shop drawings.

1.6 PROTECTIVE COATING

A. Refer Section 09960 "Protective Coatings".

PART 2 – PRODUCTS

PART 1 - FABRICATION

A. The steelwork shall be fabricated with the requirements of BS 5950 and as indicated on the
drawings. The Contractor shall obtain authorization from the Engineer to start fabrication.
Such authorization will not normally be given before all shop drawings have been checked
and approved.

B. Cuts may be made by saw, shear or gas flame provided that:

1. Structural sections required to 'exact' length are accurately cold sawn or machined.
2. The Engineer's approval is obtained for thermal cutting by hand other than for the wall
ends of beams and filler joists and for notching.
3. Shear and gas cut edges which are subject to dynamic or fatigue loading or liable to
brittle fracture have a minimum of 3mm of material removed by machining to leave a
true profile free from distortion.
4. The butting faces at caps, splices, bases, etc., of all compression members are
machined square to ensure that they are in full contact over an area sufficient to
transmit the full load.
5. Stiffeners are ground to ensure a close fit with the stiffened member.
6. The radius of re-entrant cuts is as large as possible without overcutting.
7. Care is taken up prevent excess hardening of the edges of Grade 50 and 55 steels
which are to be welded.
8. The roots of all notches to the ends of beams and girders weighing in excess of 67
kg/metre are radiuses.

C. Bolt holes in hollow sections shall be sealed to prevent the ingress of moisture.

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D. All finished members shall be free from twist, true to profile and straight or truly curved.

E. Base plates in excess of 0.50 m2 in area shall have 50mm diameter air holes to facilitate
grouting after erection of the columns.

2.2 FABRICATION TOLERANCES

A. Fabricated members shall comply with the dimensions and shapes shown on the drawings
and the accepted shop detail drawings within the tolerances set out below.

1. Length - plus or minus 2.0mm.

2. Width and depth - plus or minus 3.0mm.
3. Straightness - A member shall not deviate from the straight line joining any two
corresponding points on the ends of the member by more than one thousandth part of
the length.
4. Machined end faces - No part of any machined end face of a member other than a
column shall deviate from a plane at right angles to the axis of the member by more
than 0.5mm. No part of the machined bearing face of a column shall deviate from a
plane at right angles to the axis of the column by more than 0.25mm and 90% of the
bearing area shall have full contact uniformly distributed over the whole of the area and
substantially symmetrical about the major and minor axes.
5. Built up members:
a. The centre line of a web shall not deviate by more than 6.0mm from the plane
passing through the centre lines of the flanges.
b. A web without intermediate stiffeners shall not deviate from the plane
representing the true centreline of the web by more than the depth of the web
divided by 150.
c. A web having intermediate stiffeners shall not deviate from the plane
representing the true centreline of the web by more than the amount stated
below:
i. For D/t less than 150, the least panel dimension divided by 100.
ii. For D/t greater than 150, the least panel dimension divided by 80, where D
is the depth of the web and T is the thickness.
6. A flange shall not deviate from the plane passing through the centreline of the outer
surface and at right angles to the plane of the web by more than 3.0mm or the flange
width divided by 200 whichever is the greater.

2.3 INSPECTION AND RELEASE FOR DELIVERY OR SHIPMENT TO SITE

A. In accordance with Section 01300 of the Specification, the Contractor shall give the Engineer
reasonable notice in writing of the date on and the workshop or place at which the steelwork
will be ready for inspection and testing, as provided in the Contract, and the Engineer shall
thereupon, at his discretion, notify the Contractor of his intention either to release such
steelwork for delivery or shipment to the Site on receipt of works test certificates or of his
intention to inspect and test such steelwork. In the latter event the Engineer will, on giving
twenty four hours notice in writing to the Contractor, attend at the workshop or place so
named within ten days of the date by which the Contractor has stated in his notice that the
said steelwork will be ready for inspection and testing.

B. Whether at the workshop or place of the Contractor or of any of his sub-contractors, the
Contractor shall provide such labour, supervision, materials, electricity, fuel, water, stores,
apparatus, instruments or other things required to carry out efficiently inspection and testing
of the steelwork, in accordance with the Contract, and shall give facilities to the Engineer to
accomplish such inspection and testing.

C. At the satisfactory completion of such inspection and testing, the Engineer shall issue to the
Contractor a notification releasing the steelwork for delivery or shipment to the Site. No
steelwork shall be delivered or shipped to the Site until the Contractor has obtained from the
Engineer his notice releasing such steelwork for delivery or shipment.

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2.4 HANDLING, DELIVERY OR SHIPMENT TO SITE AND STORAGE AT SITE

A. The precautions to be taken when handling, transporting and storing steelwork shall include:

1. All wire ropes and chain slings used for hoisting and securing loads shall be covered to
prevent scoring, chaffing and other damage.

2. Softwood timber bearers with a sufficient contact area to prevent crushing shall be
provided at all stages of transporting and storage. Bearers shall be level and sufficient
in number to prevent distortion of members. Beams used to support steelwork stored
externally shall be sufficiently high to ensure that the lowest parts of the stored
members are above and clear of the rainwater splash zone and that from passing
vehicles.

3. Special consideration shall be given to the arrangements of bearers if articulated

vehicles which allow differential movement of bearers are used to transport steelwork.
Bolster wagons shall be used if long members are transported by rail.

4. Vertical timber packing’s shall be used to separate members when required and to
prevent chaffing. The methods used for securing members during transportation shall
ensure that steelwork is not damaged by the use of unprotected chains or other
equipment used to secure loads in transit.
5. Steel members shall preferably be stacked in single layers. Where conditions require
stacks or more than one layer, softwood pickings’ shall be used between layers.

6. Members shall be stacked in such a manner as to permit free drainage of rainwater

from the surfaces and to avoid bonding. If covers are provided to stored steelwork,
timber bearers or other form of support, which is acceptable to the Engineer, shall be
used to ensure that covers are not in contact with steel surfaces. The arrangements
for ventilation under the covers to minimize condensation shall be acceptable to the
Engineer.

7. Precautions shall be taken at all stages to prevent steelwork being contaminated by oil,
cement, soil, chemicals or other deleterious agents. Should any contamination occur,
the contaminating agent shall be removed immediately by swabbing or brushing and
the surfaces well washed with clean water.

8. Steelwork shall be loaded or unloaded by hoisting equipment. It shall not be moved by

sliding or skidding.

9. Small components without packing shall be handled singly and shall not be thrown on
or off vehicles or at any other time. They shall be stored on pallets and precautions
taken to prevent chaffing.

2.5 LOAD TESTING AND CERTIFICATION

A. Any lifting and runway beams incorporated into the structure shall be installed and tested in
accordance with the requirements of BS 2853 - Design and Testing of Steel Overhead
Runway Beams and Travelling Trolleys.

B. The Contractor shall submit to the Engineer six copies in English of each Test Certificate with
all test readings. The test certificate shall state the conditions under which each test was
carried out.

2.6 CERTIFICATES AND TESTING

A. When requested by the Engineer, the Contractor shall submit for approval copies of
Certificates of Origin and Mill Test Analysis Certificates for the actual steel sections being
supplied. In addition, the Engineer may require samples of steel sections, machined as

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GENERAL SPECIFICATIONS DIVISION 5 - METALS

necessary, to be submitted to an approved independent testing laboratory for analysis and

tests.

2.7 BRANDING/MARKING

A. All steel delivered to site shall be branded/marked in accordance with the british Standard
whether received from the mill or stock.

PART 3 – ERECTION

3.1 GENERAL
A. Delivery and erection of steelwork shall be carried out in a manner, which will prevent damage
of any kind to the steelwork. The Contractor shall be responsible for the stability of the
structure at all stages during erection and shall provide and remove on completion any
temporary bracings, guys and the like which are required.

B. Stanchions shall be set in position on steel wedges and packing’s. Site connections shall not
be fully tightened until sufficient sections of the structure have been plumbed, levelled and
aligned to ensure completion of the remainder without any need to strain members into
position.

C. Constructional Plant used for erection shall not impose a greater load anywhere on the
foundations of the structure than that for which they are designed for the completed use of the
building.

D. The Contractor shall have a foreman or a properly accredited charge hand on site at all times
during working hours until physical completion of the Contract. A complete set of working
drawings and specifications and instructions shall also be kept on site. The steelwork shall be
available for inspection by the Owner or his representative at all times.

E. Prior to delivery to site each separate item of steelwork shall indelibly marked in matt black
paint, in accordance with an approved marking diagram, to facilitate identification and
erection.

F. When erecting on or over concrete or other floors, care shall be taken to prevent damage to
the floors through careless handling of sections, bolts or spanners. Protection approved by the
Engineer shall be provided where it is necessary to run erection cranes and plant on the
floors.

G. The hoisting of sections which have been painted is to be carried out using slings and timber
or rubber packs to minimise damage. Chains shall not be used.

H. During erection the work shall be securely bolted or otherwise fastened and if necessary
temporarily braced to make adequate provision for all erection stresses and conditions
including those due to erection equipment and its operation.

I. Column base plates shall be raised or lowered to correct level using sawn stainless steel
packs or wedges not larger than necessary for the purpose. The engineer shall be informed
where the space between base plates and foundation is less than 10mm or more than 60mm.

J. The Engineer shall be informed of any defects due to detailing or fabrication errors and no
remedial work shall commence until the method of rectification has been approved.

K. The steel sliding surfaces of movement joints shall be coated with molybdenum disulphide
grease before connection and care shall be taken to ensure that bolts are in the centre of
slotted holes after erection of the structure.

L. Members shall not be permanently connected until sufficient of the structure has been
aligned, levelled, plumbed and temporarily connected to ensure that they will not be displaced
during the erection and alignment of the remainder of the structure.

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M. When HSFG bolts are used the method of identifying fully tightened connections (e.g. a colour
spot of paint) shall be agreed with the Engineer before erection commences.

3.2 TOLERANCES from table: 05120-3A shall be followed:

TABLE: 05120-3A

LOCATION PERMISSIBLE mm
DEVIATION
Position of first erected column +/- 10

Space between - at floor level +/- 15

- at soffit level +/- 15

Overall length and width of building plan (Up to +/- 20

40 m)
Plumb of columns (up to 3 m) +/- 8

(up to 7 m) +/- 10

Level of base of first erected column +/- 5

Level of beams - flatness +/- 10

- variation in datum +/- 20

Difference in level of ends of a beam +/- 10

All necessary ladders, scaffolds or other suitable access shall be provided to enable the Engineer to
inspect the connections.

3.3 SURFACE PREPARATION OF PAINTED STEEL WORK

A. All steelwork which is to be painted shall be blast cleaned so as to achieve a surface finish.

B. Within four hours of blast cleaning a primer shall be applied which is suitable for all
subsequent fabrication processes and the protective coating system.

C. Blast cleaning shall be carried out prior to fabrication unless the Engineer approves
otherwise.

3.4 SURFACE PREPARATION OF ENCASED STEEL WORK

A. Steelwork, which is to be encased in concrete, shall be cleaned by mechanical wire brushing

to remove all loose rust, mill scale, dirt and grease.

B. Steelwork, which is to be encased in block work, boarding, plaster, etc. in such a way as to
leave a space around it shall receive the treatment described in Clause 3.3 and shall then be
given two coats of bitumen solution to a minimum total dry film thickness of 50microns.

C. The protective treatment to any partially embedded steelwork shall extend a minimum of
75mm into the encasing concrete.

3.5 PROTECTIVE TREATMENT TO STRUCTURAL STEEL WORK

A. Unless specified otherwise in the contract documentation the protective treatment to the
structural steelwork shall be selected from the painted coating systems described in Table 3,
Part 4 of BS 5493 giving a time of first maintenance of minimum fifteen (15) years.

B. Care shall be taken to avoid the contamination of ‘non-painted’ items with paint.

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C. Before the application of succeeding coats the surfaces shall be thoroughly cleaned to
remove all traces of sand, dust, salts, oil, grease, etc. and shall be free from moisture.

D. Each coat shall be hard dry before the application of the succeeding coat which shall be a
different colour shade.

E. After erection all damaged and unsound areas and all incompletely treated areas such as
nuts, bolts and washers shall be touched-up to match the paint treatment of the adjacent
surfaces.

F. The contact surface of joints made with HSFG bolts shall be left unpainted. Any paint that
has previously been applied shall be removed by blast cleaning. Special care shall be taken
after assembly to paint all edges and corners over the joints together with bolt slots, nuts and
washers so as to prevent the ingress of moisture.

G. The contact surfaces of all joints other than as indicated shall be primed and brought together
while the paint is still wet.

H. Surfaces which will be inaccessible after fabrication or erection shall receive the same
coating system to be applied to adjacent surfaces before assembly.

END OF SECTION 05120

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