WI-10.

05 Incident Reporting and Investigation

Rev: A1 (January 2012)
Owner: …

Welding and Fabrication of

Structural Steel
Specification 001

Originator: F. Krajenbrink // Checker: C. Komen / S. Rijtema / R. Verhoog // QA Checker: G.T. Koning // Approver: J. van Akkeren
Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

CONTENTS

1 INTRODUCTION 1
Scope 1
References 1
Definitions 3
Abbreviations 3
Performance 4
Conflicting Requirements 4
Quality Management 4
Quality System Procedures 5

2 MATERIALS 6
Definitions 6
Condition of Supplied Steel 7
Certification of Steel 7
Traceability 8
Welding Consumables 8
Storage and Handling 8

3 WELDING PROCEDURE AND WELDER QUALIFICATION 9

Welding Procedure Specifications (WPS) 9
Welding Procedure Qualification Record (WPQR) 9
Pre-qualified WPS 9
Essential Variables 10
Non-Destructive Testing 10
Impact Testing (Charpy V-notch) 10
Macro Examination 10
Hardness Testing 10
Welder and Welding Operators Qualifications 11

4 PRODUCTION AND ASSEMBLY 11

General 11
Welding 11
Welding Sequences 11
Straightening of Structural Members 11
Surface and Edge Preparation 11
Assembly 12
Repair of poor fit-up 12
Tack Welds 12
Temporary Attachments 12
Preheat and Interpass Temperature 12
Post Weld Heat Treatment 13
Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Weld Dimensions 13
Compatibility of Welds 13
Weld Profile and Surface Finish 13
Weld Repairs 13

5 FABRICATION OF STRUCTURAL MEMBERS AND MATERIALS 14

General 14
Tubular connections 14
Pad Eyes 14
Splices 14
Tolerances General Requirements 15
Fabrication and Installation of grillages 15

6 INSPECTION AND NON DESTRUCTIVE TESTING 16

General 16
Qualification of Visual Welding Inspectors and NDT Operators 16
Extent of NDT for structural welds 17
Repairs and removals 17
Visual examination and finish of welds 17
Radiographic Inspection (RT) 18
Ultrasonic Inspection (UT) 18
Magnetic Particle Inspection (MPI) 18
Liquid Penetrant Inspection (LPI) 18

7 DOCUMENTATION 18
Pre-Fabrication Documentation 18
Quality Records 18
Final Documentation Packages 19
Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

1 INTRODUCTION
Scope
This specification defines the minimum requirements for welding, fabrication and inspection of
structural steelwork. As basis for all structural welding AWS D1.1 or ISO 15614-1 shall be used.

Other international recognized standards may be used after approval by Contractor.

References
The latest editions at time of contract including addenda, supplements etc. of the following Codes and
Standards shall govern the execution of the work. The Subcontractor shall provide himself with
applicable copies of all the referenced documents, and shall make them readily available to all personnel
involved in the work.
American Institute of Steel Construction (AISC)
AISC Code of Standard Practice for Structural Steel Buildings and Bridges
AISC Specification for Structural Steel Buildings
American Welding Society (AWS)
AWS A2.4 Standard symbols for Welding, Brazing and Nondestructive Examination.
AWS A5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
AWS A5.5 Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
AWS A5.17 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding
AWS A5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding
AWS A5.20 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding
AWS A5.23 Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc
Welding
AWS A5.28 Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc
Welding
AWS A5.29 Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding
AWS D1.1 Structural Welding Code – Steel
American Petroleum Institute (API)
API RP 2A Recommended Practice for Planning, Designing and Constructing Fixed
Offshore Platforms
American Society of Mechanical Engineers (ASME)
ASME BPV-V Boiler and Pressure Vessel Code Section V – Nondestructive Examination
ASME BPV-VIII Boiler and Pressure Vessel Code Section VIII – Pressure Vessels
ASME BPV-IX Boiler and Pressure Vessel Code Section IX – Welding and Brazing
Qualifications
The American Society for Non-destructive Testing, Inc. (ASNT)
SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in
Nondestructive Testing

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

The American Society for Testing and Materials (ASTM)

ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
ASTM A578 Standard Specification for Straight-Beam Ultrasonic Examination of Rolled
Steel Plates for Special Applications
ASTM E384 Standard Test Method for Knoop and Vickers Hardness of Materials
British Standards Institution (BSI)
PD 5500 Specification for unfired fusion welded pressure vessels
NEN-EN-ISO Nederlandse Norm – European Standard – International Standardization
Organization
EN 1011-1 Welding – Recommendations for welding of metallic materials – Part 1:
General guidance for arc welding
EN 1011-2 Welding – Recommendations for welding of metallic materials – Part 2: Arc
welding of ferritic steels
EN 10160 Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm
EN 10204 Metallic products – Types of inspection documents
EN 10893 Non-destructive testing of steel tubes
ISO 3690 Welding and allied processes – Determination of hydrogen content in arc weld
metal
ISO 3834-2 Quality requirements for fusion welding of metallic materials – Part 2:
Comprehensive quality requirements
ISO 6507-1 Metallic materials – Vickers hardness test – Part 1: Test method
ISO 9001 Quality management systems – Requirements
ISO 9606-1 Qualification testing of welders – Fusion welding
ISO 9712 Non-destructive testing – Qualification and certification of NDT personnel
ISO 14175 Welding consumables – Gases and gas mixtures for fusion welding and allied
processes
ISO 14731 Welding coordination – Tasks and responsibilities
ISO 15609-1 Specification and qualification of welding procedures for metallic materials –
Welding procedure specification – Part 1: Arc welding
ISO 15614-1 Specification and qualification of welding procedures for metallic materials –
Welding procedure test – Part 1: Arc and gas welding of steels and arc welding
of nickel and nickel alloys
ISO 15653 Metallic materials. Method of test for the determination of quasistatic fracture
toughness of welds (crack tip opening displacement, CTOD)
ISO 17021 Conformity assessment – Requirements for bodies providing audit and
certification of management systems
NORSOK
M-101 Structural steel fabrication
Note: Title of code does not necessarily have to be in line with the item and/or activity.

Page 2 of 26
Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Definitions
Client Principal of Heerema Marine Contractors Nederland SE (Contractor) for
the execution of projects according contract requirements between Client
and Contractor
Contractor Heerema Marine Contractors Nederland SE
Subcontractor Nominated fabricator and/or his subcontractor for the supply and/or
fabrication of structural steelwork described in the contract requirements
Recognized Certifying Lloyd’s Register, American Bureau of Shipping, Det Norske Veritas /
Authority Germanischer Lloyd (DNV∙GL), Bureau Veritas, Technische
überwachungs Verein [1]
May Indicates a provision that has equally acceptable alternatives
Shall Indicates a requirement that is mandatory
Should Indicates a provision that is preferred
[1] Only the Certifying Authorities as listed in this table are considered recognized by Contractor.

Abbreviations
AISC American Institute of Steel Construction
ANSI The American National Standard Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASNT American Society for Non-destructive Testing
ASTM American Society for Testing and Materials
AWS American Welding Society
Ceq Carbon Equivalent,
Ceq = C+(Mn/6)+(Cr+Mo+V)/5+(Ni+Cu)/15, all elements in wt%
CTOD Crack Tip Opening Displacement
EN European Standards
HAZ Heat Affected Zone
ISO International Organization for Standardization
ITP Inspection & Test Plan
NDT Non Destructive Testing
NEN Nederlandse Norm
Pcm Composition parameter,
Pcm = C+(Si/30)+(Mn+Cu+Cr)/20+(Ni/60)+(Mo/15)+(V/10)+(5B), all
elements in wt%
PWHT Post Weld Heat Treatment
QA Quality Assurance
QC Quality Control
TTP Through Thickness Properties
WPS Welding Procedure Specification
WPQR Welding Procedure Qualification Record

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Performance
Subcontractor shall designate a competent representative familiar with all phases of fabrication and
administration to which Contractor may communicate at all times.

Subcontractor shall designate during the work, at all times, competent supervision (e.g. foreman,
construction manager) experienced in structural steelwork.

Subcontractor shall employ only skilled and qualified craftsmen to perform all aspects of the work
including NDT and inspection.

Subcontractor shall submit an ITP which chronologically lists all relevant aspects covering the full
scope with related requirements (but not limited to) inspections, acceptance criteria, responsibilities and
verifying documents. For each relevant activity Subcontractor shall incorporate the kind of verification
by allocating Hold, Witness, Monitoring or Review points for approval by Contractor and if declared
applicable in the contract document(s), the Certifying Authority. Contractor considers the ITP as an
essential document.

Subcontractor shall inform Contractor and Contractor’s QC Department two (2) working days prior to
the commencement of any work.

Subcontractor shall report progress on a weekly basis or as directed in the contract.

Conflicting Requirements
Deviations from or additions to this specification and pertaining documents are not allowed unless
instructed or agreed in writing by Contractor. In case of contradicting requirements or omissions the
Subcontractor shall obtain a written ruling from Contractor before proceeding with the work affected.

As a general rule, the requirements of the referenced codes, standards, specifications, laws and
governmental regulations and the regulations of the appointed Certifying Authority, if applicable shall
be adhered to.

However, if these are less stringent than the requirements of this specification, this specification shall
be adhered to. Where the requirements of either the codes, standards, specifications, governmental laws
or the Certifying Authorities are more stringent than the requirements of this specification, the
Subcontractor shall adhere to those and inform Contractor accordingly.

Quality Management
The Subcontractor shall maintain an effective program for quality assurance and quality control,
planned with all manufacturing functions necessary to meet the requirements of the contract. The
requirements shall be met by the establishment and implementation of procedures which shall ensure
that an acceptable product or service is delivered to Contractor. The program shall ensure that quality
requirements are determined prior to commencement of manufacture and subsequently satisfied
throughout the phase of production and delivery.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Subcontractor quality systems and quality control procedures shall be in accordance with ISO 9001 or
an approved equivalent and the certificate shall be submitted for the review and approval of Contractor.

Quality System Procedures

Subcontractor shall have available for Contractor review the quality control procedures that are part of
the quality system. Should Contractor observe that insufficient procedures are available to control the
work, or that the available procedures are inadequate, Subcontractor shall produce the additional
procedures required or revise existing procedures to Contractor’s satisfaction. Subcontractor’s
procedures should address the following activities:
 Contract review and clarification;
 Control of Contractor provided materials and supplied documents;
 Purchasing and subcontracting control;
 Quality assurance, internal audits and follow up activity;
 Control of non-conforming materials and disposition of same;
 Fabrication facilities;
 Process control for fabrication;
 Compilation of records for certification;
 Welding (procedures, qualifications);
 Consumables Storage and Handling Procedure;
 Material Identification and Traceability Procedure;
 Preheating Procedure;
 Welder’s Qualifications;
 Gouging, cutting, stretching procedures;
 NDT Procedures (Visual, MPI, LPI, UT, RT) and NDT Operator’s Qualifications;
 Control and calibration of inspection, measuring and test equipment;
 Dimensional Control procedure;
 Shot blasting, cleaning and conservation;
 Mechanical completion;
 Load out, lifting plans and sea fastening;
 Compilation of as-built documentation.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

2 MATERIALS
Definitions
Contractor recognises the following types of structural steel:
Type X - Special High Strength Steel with TTP;
Type XI - Special High Strength Steel;
Type I - High Strength Steel with TTP;
Type Ia - High Strength Steel with TTP;
Type II - High Strength Steel;
Type IIa - High Strength Steel;
Type III - Primary Steel with TTP;
Type IV - Primary Steel with Charpy-V impact test at -40°C;
Type V - Primary Steel with Charpy-V impact test at -20°C;
Type Va - Primary Steel with Charpy-V impact test at 0°C;
Type VI - Secondary Steel.

The relevant types of steel shall be indicated on the approved construction drawings.

For Type I, Ia, II, IIa, III, IV, V, Va and VI shall apply that the Carbon (C) content is limited to a
maximum of 0,18% and the Ceq is restricted to 0,43%.

For Type X and XI shall apply that the Carbon (C) content is limited to a maximum of 0,20% and the
Ceq is restricted to a maximum of 0,65% for thickness ≤ 50 mm and 0,77% for thickness > 50 mm.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Type Type Minimum Charpy test Minimum Minimum TTP Internal

(prev. specified temperature average single value soundness
rev.) Yield [MPa] [°C]
1)
X - 690 -40 27J 19J Z35 t >
15
2)
XI - 690 -40 27J 19J -
1)
I I 450 -40 60J 42J Z35 t >
15
1)
Ia - 420 -40 60J 42J Z35 t >
15
2)
II II 450 -40 60J 42J -
2)
IIa - 420 -40 60J 42J -
1)
III III 355 -40 50J 35J Z35 t >
15
2)
IV IV 355 -40 50J 35J -
V V 355 -20 27J 19J - -
Va - 355 0 27J 19J - -
VI VI 235 - - - - -
Table 1
1) Ultrasonic Testing shall meet the requirements of EN 10160 class S3 / E2 , or ASTM A578 level C
2) Ultrasonic Testing shall meet the requirements of EN 10160 class S 1 / E2 , or ASTM A578 level B

For further details, reference is made to the Contractor’s Specification 007 Structural Material
Specification. Subcontractor may propose equivalent alternatives; acceptance of materials is to the sole
discretion of Contractor.

Condition of Supplied Steel

Each structural member shall be inspected to determine extent of any corrosion or other mechanical
damage (e.g. pitting, dents, straightness, etc.) which would impair structural integrity. Unacceptable
materials shall be removed from the work site.

Certification of Steel
Material received without certification shall not be used in fabrication and kept in quarantine until
material certificates are received and controlled against the requirements described in Chapter 2 of this
specification and the Contractor’s Structural Material Specification.

Structural steel (all Types) shall be delivered with following type of certificate:

EN 10204 / 3.1 minimum, with the following explicit condition that materials are made in a steel mill
(world-wide origin) which is approved by a Contractor-recognized Certifying Authority. The materials
supplied shall be within the approval range of the Certifying Authority, i.e. type of product, category,
grade and thickness/diameter.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

An EN 10204 / 3.2 certificate shall be applicable in case the materials supplied are outside the approval
range of the Certifying Authority, or when specified in a contract document.

Steel for non-load bearing structures such as cable ladders and cable strips, shall be at least supplied
with EN 10204 / 2.2 certification. Verified true copies of original stamped certifications shall be
supplied for all materials.

Traceability
The Subcontractor shall ensure that transfer of marking to the materials is strictly controlled so that any
material can be easily identified and kept traceable to the material certificates. Marking shall be done
by means of hard stamping, stencilling or permanent markers.
Transfer of marking of materials with EN 10204 / 2.2 certification is not mandatory.

Welding Consumables
The welding consumables used in fabrication shall be approved by a recognized Certifying Authority
and selected to produce welds with mechanical properties equivalent to those required for the base metal
and shall be subject to approval by Contractor prior to use. Welding consumables for the work shall be
supplied with an EN 10204 / 2.2 certificate as a minimum.

Except for solid wires, all consumables shall be classified as low hydrogen type. Low hydrogen
consumables are defined as those that produce deposit weld metal with no more than 5ml/100g
diffusible hydrogen. For self-shielded flux cored wire, hydrogen content of no more than 8ml/100g
weld metal may be accepted.

All consumables shall comply with one of the following codes, or an approved alternative:
GMAW AWS A5.18;
GTAW AWS A5.18;
FCAW AWS A5.20, A5.29;
SAW AWS A5.17, A5.23;
SMAW AWS A5.1, A5.5;
Shielding Gases ISO 14175.

Hydrogen testing shall be according to ISO 3690.

Storage and Handling

All welding consumables shall be stored and/or baked as recommended by the consumables
manufacturer. Vacuum packed electrodes shall be used and controlled in accordance with manufacturer
recommendations. All unidentifiable, damaged, wet, corroded, expired or otherwise contaminated
consumables shall be removed from the work site.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

3 WELDING PROCEDURE AND WELDER QUALIFICATION

Welding Procedure Specifications (WPS)
Welding procedure specifications shall be prepared and qualified in accordance with AWS D1.1, or ISO
15609-1 and ISO 15614-1 and shall be approved by Contractor before use.
Approval of the WPS by a Certifying Authority shall be applicable when directed in the purchase order.

Two weeks prior to commencement of any welding, the Subcontractor shall submit to the Contractor a
weld register (i.e. a detailed summary table) of all the WPS(s) intended for use, including the mentioned
WPS(s) in their complete form. The weld register shall detail the characteristics and scope of use of each
WPS. A WPS shall be made for production welds (i.e. main welds), repair welding of main welds and
base materials, buttering, and tack welding.

Welding Procedure Qualification Record (WPQR)

The complete trajectory of qualification welding shall be witnessed and approved by a Recognized
Certifying Authority.
A WPQR shall consist of following documentation, as a minimum:
1. Certificate of Recognized Certifying Authority;
2. As-run parameter record sheet including joint details;
3. Laboratory mechanical test report;
4. Material certificate of used base material;
5. Material certificate of used welding consumable;
6. NDT report (annotation only on Certificate of Recognized CA may be accepted);
7. Details of PWHT, if applicable.

The WPQR is only valid for the workshop and other workshops under the same technical and quality
management of Subcontractor.
Existing WPQR may be accepted by Contractor without further tests, provided that the WPQR is
acceptable to the requirements of this specification. Standards which are part of existing WPQR’s and
currently replaced (i.e. BS 7448 which is replaced by ISO 15653) may be accepted provided the
requirements of this specification are met and the test results have been found acceptable by HMC.

Pre-qualified WPS
Pre-qualified welding procedures as defined in AWS D1.1 Section 3 may be used to following
conditions:
1. Non load bearing members only;
2. Minimum specified yield of base materials no more than 250 MPa;
3. Base metal thickness max. 19 mm (3/4”).
Use of pre-qualified welding procedures shall be subject to the sole approval of Contractor.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Essential Variables
A qualified WPS shall be used within the limitations of the essential variables set forth in AWS D1.1
or ISO 15614-1 and following supplement:
 Base materials
When the steel to be welded has a Pcm ≥ 0,20, or a carbon content C ≥ 0,12%, then an increase of
more than 0,03 Pcm units or 0,04 CE (IIW formula) units over the value on the approval test shall
require a new qualification test.

Non-Destructive Testing
The test weld shall be non-destructively tested in accordance with §6.3, Table 1, Inspection category A
of this specification.

Impact Testing (Charpy V-notch)

Impact testing shall be carried out according AWS D1.1 or ISO 15614-1, on butt weld tests at the
following locations on the cap side.
 Weld centre line;
 Fusion line - (bevel side);
 Fusion line + 2mm - (bevel side);
 Fusion line + 5mm - (bevel side).

When actual qualification or production weld thickness exceeds 50mm (2 inch) also impact testing in
the root region at the same locations as cap side is required. Three test specimens will be required for
each set. Specimens shall be sampled a maximum of 2 mm below the surface of the parent metal and
transverse to the weld. For double sided welds (e.g. X or K joint) the specimens shall be sampled in the
root area.

The minimum Charpy energy values to be obtained at the relevant test temperature for the types of steel
listed in table 1, or as per base metal requirements whichever is more stringent.

Macro Examination
A macro section shall be prepared and examined in accordance with AWS D1.1 or ISO 15614-1.

Hardness Testing
Vickers hardness test shall be performed on the macro-etched specimen using 10kg load according ISO
6507-1 or ASTM E384. Hardness tests to be taken within 2mm from the plate surface at the cap and
within 2mm from the root. These tests shall establish the hardness of the base materials, weld metal and
the maximum hardness in the HAZs. Exact hardness indent locations shall be reported. The maximum
permissible hardness acceptable in the HAZs, at any point of sampling, shall be as follows:
 Steels having specified minimum yield ≤460MPa: 350HV10;
 Steels having specified minimum yield >460MPa: 420HV10.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Welder and Welding Operators Qualifications

Welders, welding operators and tack welders shall be qualified in accordance with AWS D1.1
or ISO 9606-1

The qualifications shall be certified by a Recognised Certifying Authority.

Certification based on X-ray inspection only, shall not be accepted.

Existing valid welder qualification certificates may be accepted providing it can be demonstrated that
the welders are adequately qualified and are currently engaged on work, whereby the welder’s
performance sheet shall be re-endorsed by a Recognized Certifying Authority. Any such records will
be presented to Contractor for approval prior to the planned start of fabrication.

4 PRODUCTION AND ASSEMBLY

General
All construction work shall be executed in accordance with this specification, the drawings, and the
relevant procedures approved by Contractor.

The Contractor shall apply a weld traceability system for identification on all shop drawings. i.e.
welding, welder, inspection and NDT reports, WPS etc. is controlled and traceable to supplied item.

Welding
All welding shall be carried out to the recommendations given in AWS D1.1 and/or EN 1011-1/2.

Welding Sequences
When required contractor shall develop welding and assembly sequences to minimise distortion and
residual stresses in the structure.

Straightening of Structural Members

Members distorted by welding shall be straightened by appropriate mechanical means or by carefully
localised heat according to a detailed work procedure and instruction. If hot straightening is proposed,
the maximum temperature shall not exceed the temperature limit recommended by the steel
manufacturer, but it shall in no case be higher than 500ºC.

Surface and Edge Preparation

Edges to be welded shall be prepared by machining, or by thermal cutting followed by grinding to bright
metal. Welding through primer coating shall not be accepted.
All weld preparations shall be subject to visual inspection. The surfaces and edges shall be smooth
uniform and free from fins, tears, cracks and other material that will prevent proper welding. Any
defects found shall be dressed out by grinding, minimum thickness shall not be contravened. If the depth
of excavation on the weld bevel exceeds 5 mm, a weld repair shall be made according an approved
WPS.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Assembly
The parts to be joined by butt welds shall be carefully aligned. Weld preparation tolerances shall comply
with the approved WPS and the tolerances given in AWS D1.1 unless otherwise indicated on the
contract drawings. Where butt welds are to be made between different thicknesses, a transition using a
taper of 1:4 (or noted otherwise on the drawing) shall be provided.

The parts to be joined by fillet welds shall be brought into as close contact as possible. However, any
root gaps in fillet welds shall be no more than 5 mm and compensated by a corresponding increase in
fillet leg length.
No welding shall be started until the structure has been properly aligned and fitted. The structural
members shall be held in position by clamps, bridge plates, bullets, tack welds or other suitable means.
All welding shall be based on an approved WPS. Permanent backing strips shall not be accepted, unless
shown in design drawings.

Repair of poor fit-up

Root gaps, which are out of tolerance, shall be corrected by grinding or buttering followed by grinding,
back to the required tolerance. Buttering passes shall be applied according to an approved buttering
procedure. The thickness of buttering on any member shall not exceed 2t of the thinner part or 19 mm
whichever is less. Buttered layers shall be subject to 100% Visual Inspection before welding the joint.
The UT inspector shall be informed about the buttering prior to the UT examination of the completed
weld.

Tack Welds
Tack welds shall be of a minimum length of four times the base metal thickness or 50 mm, whichever
is less, and shall be carried out in accordance with an approved WPS. Tack welds that form part of the
completed weld shall be ground to a featheredge, crack detected by means of MPI and fused with the
root run.

Temporary Attachments
Temporary attachments such as lifting lugs, lugs for scaffolding and other fabrication and erection aids
shall be removed subsequently. Removal shall be by arc-air gouging or cutting to a minimum of 3 mm
above the surface of the base metal and the remainder shall be ground flush. The ground area shall be
subject to 100% Visual Inspection and 100% MPI, to ensure all discontinuities have been properly
removed.

All welding of attachments shall comply with the requirements for the structure to which they are
attached. Removal of temporary attachments by hammering shall not be permitted.

Preheat and Interpass Temperature

The minimum preheat temperature for each joint shall be determined by the applicable and approved
WPS. . The Subcontractor shall provide adequate temperature measurement to ensure conformity to the
specified preheat and interpass temperature.

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

Post Weld Heat Treatment

PWHT shall be according PD5500:2003 clause 4.4.3 and 4.4.5 or AWS D1.1 or ASME VIII Division
1. Procedures for PWHT shall include:
 Heating rate;
 Cooling rate;
 Soaking temperature and time;
 Heating facilities;
 Insulation;
 Control devices;
 Recording equipment, including calibration details;
 Sketch illustrating the method of support;
 Number and location of thermocouples.
Latest calibration of recording equipment not to exceed 1 year.

Weld Dimensions
All structural welds shall conform to the types, sizes and extent detailed on the drawings. In the absence
of specific instructions all weld joint dimensions shall conform to AWS D1.1. All structural welds shall
be continuous and shall have complete penetration , unless noted otherwise.

Compatibility of Welds
All welds shall develop the strength, ductility and impact properties specified for the steel being welded.
Welds forming connections between steel of different grades shall develop, as a minimum, the same
unit strength as that specified for the lower strength steel and shall develop values of ductility and
impact properties, as a minimum, equal to the lower value of those specified for the grade of steel being
joined.

Weld Profile and Surface Finish

Welds shall be in the as welded state unless noted on construction drawings. All welds shall be of the
specified size and shape, and shall be blend smoothly into the parent material without overlap or
unacceptable undercut. The weld surface and the adjacent area of the weld shall be clean and free of all
dirt, grease, paint, weld spatter etc.

Weld Repairs
All unacceptable welds shall be reported. The Contractor shall repair or replace all welds that do not
meet the requirements of the appropriate codes and standards and this specification.

Removal of defects and deposition of repair welds shall be in accordance with an approved WPS. When
a WPS qualified for the original weld is used to cover repairs, pre-heat shall be increased 50°C above
that qualified. Removal of defective weld metal or portions of the base metal shall be done by
machining, grinding, chipping, arc-air gouging and any other method, which produces a clean,
uncontaminated surface. Oxygen-acetylene gouging shall not be accepted. Prior to arc-air gouging,

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Spec 001 Welding and Fabrication of Structural Steel
Rev: B (June 2015)

preheat shall be applied, whereby the repair area shall be preheated as per applicable WPS used to
perform repair welding.

All arc-air gouges shall be ground to bright metal to remove residual carbon. The defect and 25mm of
sound metal beyond each end of the defect shall be removed. Each excavation shall be subject to 100%
Visual Inspection and 100% MPI (dry powder method may be accepted) to ensure complete removal
of the defect.

All repair welds shall be re-examined in accordance with Chapter 6 of this specification.

5 FABRICATION OF STRUCTURAL MEMBERS AND MATERIALS

General
All fabrication and tolerances shall conform to the approved design drawings and comply with ISO
13920 (tolerance class as specified on drawing), NORSOK M-101 Edition 5 October 2011 Annex E
and this specification.

Tubular connections
When two or more tubulars join in an X-joint, the large diameter member shall continue through the
joint, and the other shall frame onto the through member and be considered the minor member. Unless
specified otherwise on the drawings, when two or more minor members intersect or overlap at a joint,
the order in which each member frames into the joint will be determined by wall thickness and/or
diameter. The member with the thickest wall will be the continuous or through member, and the
sequence for framing the remaining members shall be based on the order of decreasing wall thickness.
Should two or more members have the same wall thickness, the larger diameter member shall always
be the continuous or through member.

Pad Eyes
Direction of force on pad eyes shall be essentially in line with the rolling direction of the steel plate.
Direction of rolling of the steel plate with respect to cutting of the pad eye shall require verification of
the steel nesting plan, and shall be documented in the as-built files. Contractor shall drill and ream all
pad eye pin holes after welding of cheek plates. Splices in any pad eye plate shall not be accepted.

Splices
Structural members may be spliced for economic use of material, within the specified requirements and
to be agreed with and approved by Contractor. Any splices shall develop the full strength and cross
section of the member joined.

Welded joints of axially aligned structural members of different material size; thickness, diameters or
widths shall be made in such a manner that the slope through the transition zone does not exceed 1:4,
unless noted otherwise. The transition shall be accomplished by chamfering the thicker part, , sloping
the weld metal, or by combination of these. The locations of all splices shall be in accordance with the
requirements as specified in §5.4.1 and §5.4.2.

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5.4.1 Structural Tubulars

Butt splices in tubulars shall have the longitudinal seam radially offset by not less than 45° or 300mm
circumferential whichever is more. Splices shall not be located closer together than 1000 mm, or one
(1) diameter of the pipe, whichever is less. There shall not be more than two (2) splices in any 3000mm
interval of pipe.

5.4.2 Beams - Structural Shapes

Butt splices in fabricated girders shall minimize the use of cope holes (mouse holes) for welding access,
by splicing webs prior to mating with the flange. The use of the beam shall determine the location and
frequency of splicing.

Splices shall not be located closer together than twice the depth of the beam, or 1000 mm whichever is
smaller. Other splice locations may be used subject to approval by Contractor. There shall not be more
than two splices in any 3000 mm interval of structural shape. In cantilever beams, there shall be no
splice located closer to the point of support than one-half of the cantilevered length. For beams in any
span between supports, there shall be no splice in the middle one-fourth of any span, nor in the eighth
of the span nearest any support, nor over any support. The location of all splices in critical members is
subject to the approval of Contractor. Splicing in beams and shapes shall not be allowed underneath
bearing-pads.

Tolerances General Requirements

The Subcontractor shall provide all personnel, equipment and instruments required to monitor and
control dimensions and tolerances. Instruments used shall be in accurate adjustment and shall have
valid calibration certificates.

Reference temperature for survey activities shall be room temperature. The allowable tolerances given
for individual members shall not cumulate to give unacceptable deviation for the finished section or
complete structure, i.e. chain dimensions shall be avoided.

If tolerances given for individual sections and components are conflicting, those tolerances representing
the stricter values shall be governing. If no appropriate tolerance is specified, the tolerance requirements
shall be agreed.

In assembling and joining parts of a structure or of built-up members and in welding reinforcing parts
to members, the procedure and sequence (e.g. step back technique in root) shall be as such to minimize
distortion and shrinkage. As far as practicable, all welds shall be made in a sequence that will balance
the applied heat during welding. Dimensional tolerances of built-up members, including deviation from
straightness and deviation from specified camber, shall conform to the requirements of ISO 13920
(tolerance class as specified on drawing) and NORSOK M-101 Edition 5, October 2011 Annex E.

Fabrication and Installation of grillages

All barge dimensions, web frame locations and levels to be confirmed by Subcontractor prior to
commencing fabrication. Barge data shown on drawings is considered nominal only. Subcontractor

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shall ensure that full bearing is achieved at the grillage/barge pack locations and shall apply shimming,
if necessary. Grillage beams shall be set out relative to each other and relative to the centre line of barge.

Load out grillage and seafastening shall be fabricated and installed in accordance with acceptable
tolerances for relevant structures defined in this document. Specific tolerance requirements shall be
shown on respective drawings and shall be mandatory.

Location of wing plates to barge frames to be within +/- 5mm of frame C.L., bulkhead C.L or bulb flat
C.L. Subcontractor to ensure that the relative level at bearing and skid surfaces are coplanar within 5mm
with the barge at simulated tow ballast condition to be advised by Contractor.

6 INSPECTION AND NON DESTRUCTIVE TESTING

General
The Subcontractor shall be responsible for the execution of all the inspection and NDT required by this
Specification. Any inspection by Contractor or Certifying Authority shall not absolve the
Subcontractor(s) of this responsibility.

NDT shall only be executed based on approved examination procedures for each of the NDT technique.
Contractor shall have unlimited access and the right to inspect the material, fabrication and erection of
all items covered by the contract. Subcontractor shall ascertain that all welding is performed in
accordance with this specification and any written addenda approved by Contractor.

Final inspection and NDT of structural steel welds shall be carried not earlier than 24 hours after
completion. For Type X and XI steels, the NDT delay time shall be 48 hours minimum. Final inspection,
including NDT, on welds subject to PWHT may be performed when all heat treatment have been
completed.

In the case of welds whose inspection is critical to the fabrication schedule, exceptions to the 24 hour
wait may be made on a case-by-case basis. This shall not be possible for materials having a minimum
specified yield strength exceeding 460 MPa.

Qualification of Visual Welding Inspectors and NDT Operators

Visual Welding Inspectors shall be qualified according ISO 9712 Level II, CSWIP 3.1, AWS CWI or
an approved equivalent. NDT Operators shall be qualified to meet the recommendations of ASNT-TC-
1A Level II (ACCP), ISO 9712 Level II or an approved equivalent. NDT Operator qualifications shall
be approved by Contractor prior to commencing inspection activities.

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Extent of NDT for structural welds

Inspection Type of Visual Extent of testing
Category Connection Examination
RT UT MT
1)
A Butt weld 100% 100% 100%
Partial pen. weld 100% - - 100%
Fillet weld 100% - - 100%
1)
B Butt weld 100% 50% 2) 100%
Partial pen. weld 100% - - 100%
Fillet weld 100% - - 100%
1)
C Butt weld 100% 20% 2) 20% 2)
Partial pen. weld 100% - - 20% 2)
Fillet weld 100% - - 20% 2)
D All Types 100% - - 10% 2)
Table 1
1) For thicknesses where the use of ultrasonic examination is impractical, or where t<8mm, radiography shall
be used.
2) The 10/20/50% - examinations shall be interpreted as follows:
 For welds < 1 meter in length, the percentage of welds to be examined shall mean a percentage of the
connection of the given type;
 For welds ≥ 1 meter in length, the percentage of welds to be examined shall mean the partial examination
of the stated length of each weld.

Fatigue sensitive locations such as welded plate ends, mouse holes, cruciform joints, fillet welded lap
joints, etc. shall be especially part of the 10/20/50% - examinations.

If an unacceptable amount of indications are detected during 10/20/50% - examinations, specified

percentage shall be increased to 20/40/100% respectively at the instruction of Contractor or Certifying
Authority. To the discretion of Contractor or Certifying Authority, an investigation shall be carried out
to find the root causes of the indications by assessing, but not limited to the WPS, welding consumables,
weld preparations, welder performance, etc.

Repairs and removals

For surfaces ground after the removal of welded attachments and where repair of defects are removed
by means of grinding, the area shall be subject to 100% visual examination and 100% MPI. Weld repairs
shall be subject to 100% inspection by the methods required for the original weld plus a minimum of
100mm on each side of the repaired area.

Visual examination and finish of welds

Visual examination shall be carried out in according AWS D1.1.
Welds shall be inspected in the as welded state unless noted on construction drawings. All welds shall
be of the specified size and shape, and shall be blend smoothly into the parent material without overlap
or unacceptable undercut. The weld surface and the adjacent area of the weld shall be clean and free of
all dirt, grease, paint, weld spatter etc.

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Radiographic Inspection (RT)

Radiographic testing shall be carried out in accordance with ASME V, Article 2.
The acceptance criteria shall comply with ASME VIII Division 1 appendix 4.

Ultrasonic Inspection (UT)

Ultrasonic testing shall be carried out in accordance with ASME V, Article 4.
The acceptance criteria shall comply with ASME VIII Division 1, appendix 12.

Magnetic Particle Inspection (MPI)

Magnetic article inspection shall be carried out in accordance with ASME V, Article 7.
The acceptance criteria shall comply with ASME VIII Division 1, appendix 6.

Liquid Penetrant Inspection (LPI)

Liquid Penetrant testing shall be carried out in accordance with ASME V, Article 6.
The acceptance criteria shall comply with ASME VIII Division 1, appendix 8.

7 DOCUMENTATION
Pre-Fabrication Documentation
Prior to commencement of any part of the fabrication, the Subcontractor shall submit for Contractor
approval the following documentation and procedures as a minimum requirement for the contract.
 ITP;
 WPS(s) and WPQR(s);
 Welder’s Qualifications;
 Material Identification and Traceability Procedure;
 Consumables Storage and Handling Procedure;
 NDT Procedures;
 NDT Operator’s Qualifications;
 Dimensional Control Procedures.

Quality Records
The Subcontractor shall maintain quality records as documentary evidence of conformance to quality
requirements. Quality records shall be made available to Contractor for analysis and review on a weekly
basis.

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Final Documentation Packages

The Subcontractor shall provide Contractor a final as-built documentation package covering each
fabricated section or sub-assembly within 7 working days after completion of product.

The final documentation package shall contain objective evidence the related items are fabricated
conform the specified requirements set in the purchase order. Subcontracting will not relief
subcontractor from the obligation to meet these final documentation requirements. The HMC QC
Inspector will monitor, and shall be given the opportunity to review whenever requested, the progressive
built up of the final documentation during fabrication and give guidance where needed.

All data shall be suitable for photocopying (i.e. A4/A3 size) and to be of a reproducible quality to
facilitate computer processing. The documentation package shall be set-up as per index described in
this section.

There shall be no change in the sequence of this index as listed in this section. If a section will be void,
this will be noted on the front/first page of the applicable section. In case a section needs to be added,
amending the index will be subject to approval of the HMC QC Coordinator. Sections shall be divided
by numbered dividers. Subsections shall be divided by a colored paper with subsection number and title
in bold letter of minimum height 24. Letter type to be Times new roman.

After completion the HMC QC Inspector will perform preliminary review of the final package. The
fabricator shall scan the final documentation to digital format and issue for review to HMC for the
allocated HMC QC Coordinator to comment on. Comments shall be addressed, original as-built
documentation amended as such and digitally reissued for review. After approval by HMC QC
Coordinator the original hard copy final document package shall be sent to HMC.

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Final Documentation Index

Section 1 General Information

1.1 Scope of Work / Purchase Order /Work Package
1.2 Certificate of Conformity
1.3 Certificates Certifying Authority
1.4 Technical Queries (TQ)
1.5 Non Conformance Report (NCR)
1.6 Inspection Release Notes (IRN)

Section 2 Project Execution

2.1 Inspection & Test Plan (ITP)
2.2 Progress Reports

Section 3 Structural Information

3.1 As built drawings
3.2 Cutting sheet / nesting plan (pad eyes)
3.2 NDE / Weld record sheet
3.3 Post Weld Heat Treatment (PWHT) Procedure & Records

Section 4 Dimensional Control

4.1 Dimensional Control Procedure
4.2 Dimensional Control Report

Section 5 Welding
5.1 Welding Procedure Specification (WPS)
5.2 Welding Procedure Qualification Record (WPQR)
5.3 Welder Qualifications & Register

Section 6 Non-Destructive Testing (NDT)

6.1 NDT Procedures
6.2 NDT Operator Register & Qualifications
6.3 NDT Reports

Section 7 Material Information

7.1 Material Register
7.2 Material Certificates
7.3 Welding Consumable Register & Certificates

Section 8 Coating Information

8.1 Coating Specification / Procedure
8.2 Coating Inspection Reports
8.3 Coating Consumable Register & Material Data Sheets (incl. MSDS)

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Section 9 Subcontracted / Procured Items

9.1 Item title
9.2 Item title
Etc.

Section 10 System Information

10.1 Electrical
10.2 Hydraulic/pneumatic
10.3 Flow Diagrams
10.4 Piping and Instrumentation Diagrams
10.5 Manuals

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Section 1 General Information

1.1 Scope of work / Purchase Order / Work Package

 This section shows what is purchased. An un-priced copy of the PO,
internal order, work package, work instruction or similar will be
found in this section. Also included but not limited to MTO’s,
design drawings and shipping list.

1.2 Certificate of Conformity

 Statement from fabricator the product has been fabricated as agreed
and according specifications/guidelines. Statement stamped and
signed by the fabricator representative (Project Manager) on
subcontractor letter paper.

1.3 Certificate of Certifying Authority

 When applicable this section shall hold the certificates raised by the
Certifying Authority. In case of multiple certificates, these shall be
sorted in a logical order. Hard copy of original final documentation
shall not be send without the certificate from certifying authority.

1.4 Technical Queries (TQ)

 A TQ shall be raised in the event requirements can not be met. Each
change from agreements, specifications, original work scope i.e. PO
shall be subject to a TQ and shall be submitted to the QC
Coordinator for approval by discipline specialist. This shall be
logged as clarification is needed in the future.

1.5 Non Compliance Record (NCR)

 A NCR, applicable to the PO and/or fabricators procedures, must to
be closed before sending the original hard copy to HMC.

1.6 Inspection Release Notes (IRN)

 An IRN shall be raised by HMC QC Inspector (on HMC format)
when the product is fabricated and ready to be shipped. When
needed a punch list shall be added to the release note. The punch list
will register unfinished/outstanding items/actions, upon shipping,
related to the procured item/structure. The applicable release note
shall be referenced on the punch list.

 Release notes from certifying authority shall be included in this

section.

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Section 2 Project Execution

2.1 Inspection and Test Plan (ITP)

 The ITP is the tool for QC to cover inspection points before start,
during each production step and upon completion of the project.
Each step and verification point to be agreed before start of
production at the Kick of Meeting (KoM). In case of a short term
project (shorter than 2 weeks) the ITP must be send to the HMC QC
Coordinator for approval before fabrication commence. The ITP
shall have no sign of boxes for parties not involved in the fabricated
item.

2.2 Progress Report

 The subcontractor shall provide a weekly progress report, which
shall be added to the final documentation. When the schedule is
updated the schedule’s next revision must be attached to the
progress report.

Section 3 Structural Information

3.1 As-Built Drawings

 As-Built drawings shall show final dimensions of the subject,
including all approved changes. Drawing may be red stamped as
such “AS-BUILT” or updated as “Rev. Z” showing in the header
“AS-BUILT” and not showing the statement “For Construction”.
Drawings shall be signed, dated and stamped with (sub) contractor
QC/contractor stamp.

3.2 NDE / Weld Record sheet

 The document shall cross reference welds, NDE records, welders
and drawings. Listing of the welds per drawing showing welder, the
related NDE Reports and its result.

3.3 Post Weld Heat Treatment (PWHT) Procedure & Records

 When applicable to the item the PWHT records shall be
incorporated in this section. Records shall be suitable for
photocopying (i.e. A3/A4 size).

Section 4 Dimensional Control

4.1 Dimensional Control Procedure

 Procedure showing method of measuring, in some cases
subcontracted e.g. involving total station.

4.2 Dimensional Control Report

 All dimensions with a tolerance mentioned on the drawing and vital
dimensions to be identified i.e. interfaces, shall be reported. When

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subcontracted a report shall be submitted by the subcontractor on

subcontractor format signed by subcontractor and contractor.

Section 5 Welding

5.1 Welding Procedure Specification (WPS)

 All WPS’s approved by HMC to be used during the project shall be
found in this section. Preceding a register listing the WPS’s used.

5.2 Welding Procedure Qualification Record (WPQR)

 All WPQR’s which have been used to make the WPS’s shall be
found in this section, preceding a register listing the WPQR’s used.
The WPQR’s shall have a colored front page stating the WPQR
number. WPQR summary sheet suffice, to be agreed with HMC QC
Inspector.

5.3 Welder Qualifications & Register

 The qualified welding register shall only list the welders welded on
the fabricated item. Register shall be signed by the subcontractor,
HMC and if applicable the certifying authority e.g. Lloyds, DNV, as
verification welders are qualified. Register shall list the name,
welder-ID, validity dates, and range i.e. welding position of the
qualification. Copies of the welder certificate to be incorporated in
this section.

Section 6 Non-Destructive Testing (NDT)

6.1 Non Destructive Testing Procedures

 This section shall hold all NDT procedures used during fabrication.
Procedures shall be divided by colored paper, stating the discipline
and sorted in of the following order:
 VT reports
 MPI reports
 UT reports
 RT reports
 PT reports

6.2 NDT operator Register & Qualifications

 The register shall only list the Operators who performed NDT on the
fabricated item. Register to be signed by subcontractor, HMC and if
applicable the certifying authority e.g. Lloyds, DNV, as verification
qualifications have been reviewed and approved. Register shall list
the name, process and validity dates of the qualifications. Copies of
the certificates to be incorporated.

6.3

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NDT reports
 NDT reports shall be in this section as per inspection process in
numerical order, divided by a coloured paper per discipline ordered
as below.
 VT reports
 MPI reports
 UT reports
 RT reports
 PT reports
Section 7 Material Information

7.1 Material Register

 Document cross referencing the material as per position number on
the drawing to the actual material certificate. One register per
drawing listing pos number, heat number, certificate number starting
at 1(not being the mill certificate number), dimensions, if applicable
ID/plate/pipe number.

7.2 Material Certificates

 In this section the certificates shall be found which have been used
for fabrication of the item, including procured items e.g. valves,
bolts, nuts, gaskets etc. The certificates shall be divided by a
coloured paper stating the certificate number starting at 1 followed
by 2, 3, 4,…etc.

7.3 Welding Consumable Register & Certificates

 Certificates of the welding consumables including a register listing
the welding consumables used. The register shall be signed by the
subcontractor, HMC and if applicable certifying authority e.g.
Lloyds, DNV.

Section 8 Coating Information

8.1 Coating Specification / Procedure

 When coating is required this shall be done according the procedure
and or specification found in this section.

8.2 Coating Inspection Reports

 As proof coating has been done according the procedures and or
specification the coating reports will come under this section.

8.3 Coating Consumable Register & Material Data sheets incl. MSDS
 As the fabricated item might need be recoated HMC need
information and make sure the coatings are compatible.

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Section 9 Subcontracted / Procured Items

9.1 Item title

 Subcontracted items shall have the final documentation lay out as
described in this specification.
9.2 Item title
Etc.

Section 10 System Information

10.1 Electrical
10.2 Hydraulic/pneumatic
10.3 Flow diagrams
10.4 Piping and Instrumentation Diagrams
10.5 Manuals

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