SKILLS M03E Execution EN1090

SKILLS Project
FABRICATION AND EXECUTION – EN1090
NOTE: This learning module is designed to be used

together with the EN1090 standard.
LEARNING OUTCOMES
 EN1090, a new standard for fabrication and execution of

steel structures.
 Execution Classes (EXC).

 How to choose the right EXC?.
 CE Marking for steel structures.
 Designer's involvement in the requirements for fabrication

and execution.
 Technical requirements for fabrication and execution.
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LIST OF CONTENTS
 Introduction. Regulatory framework.
 Execution Classes (EXC)
 CE Marking (EN 1090-1)
 Fabrication and execution (EN 1090-2)
 Conclusion
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INTRODUCTION. REGULATORY FRAMEWORK
 The Construction Products Directive (CPD)

(Council directive 89/106/EEC)
 Mandatory provision in the European Union for “any
product which is produced for incorporation in a
permanent manner in construction works, including both
buildings and civil engineering works”
 Objectives:
 Ensure the free movement of all construction
products within the EU.
 Remove technical barriers to free trade.
 Ensure the same quality standard for all European Union
countries.
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 The CPD essential 1. Mechanical resistance and stability.

2. Safety in case of fire.
requirements: 3. Hygiene, health and the environment.
4. Safety in use.
5. Protection against noise.
6. Energy economy and heat retention
 Compliance with the essential requirements:

 Harmonised European standards (technical and
manufacturing requirements for each construction
product).
 Each Harmonized Standard covers a particular product.
 The complete list of Harmonized standards and their
status (in force, approval stage, etc..) is available at the
CEN, European Committee for Standardization:
ftp://ftp.cen.eu/CEN/Sectors/List/Construction/Snapshot.pdf
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 There are other methods to meet the essential requirements

(eg ETA certificates for products).
 The European Directive on Construction Products (CPD) will be
replaced by the European Regulation for Construction
Products (CPR).
 The CPR will have superior legislative status than the CPD and
will be "mandatory" for all EU countries .
 Nowadays, the CPR has been approved by the European
Commission. Only Articles 1, 2 ,29 – 35, 39 – 55, 64, 67, 68 and
Annex IV come in to force immediately. Articles 3 – 28, 36 – 38,
56 – 63, 65, 66 and Annexes I, II, III and V come in to force on
1st July 2013.
 So, most of the CPD remains in force until 1st July 2013
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Regulatory framework  EN 1090-1: Requirements for conformity

for steel structures assessment of structural components.
 Regulates the CE marking in steel structures.
 It does not contain rules for the design
(Eurocodes) or for the execution (EN 1090-2
or EN 1090-3).
 EN 1090-2: Technical requirements for
steel structures.
 Fabrication and execution requirements to
ensure appropriate levels of resistance and
mechanical stability, according to the
intended use and durability
 EN 1090-3: Technical requirements for
Fabrication
Design & Execution aluminium structures
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 EN 1090. Calendar
 EN 1090 was published in the OJ in 17-12-2010, by what
already it can be applied.
 The end of the period of coexistence with the national
procedure (DOW) is 01-09-2014.
 From the date of DOW, EN 1090 will be mandatory.
 Basic standards for construction products
STANDARD PRODUCT DOW
EN 10025-1 Hot rolled products of structural steels 31/08/2006
EN 10219-1
Cold formed welded structural hollow sections 31/10/2006
EN 10210-1
EN 14399-1 High-strength structural bolting assemblies for preloading 30/09/2007
EN 15048-1 Non-preloaded structural bolting assemblies 31/10/2009
EN 10088-5 Stainless steels 31/12/2010
 Full list -> EN 1090-1 § 2 + EN 1090-2 § 2
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EXECUTION CLASSES (EXC)
 The “Execution Classes” is one of the most important new

concepts introduced in EN 1090.
 Come from the Eurocode 0 (EN 1990) and will be trasnferred

to an Annex of Eurocode 3 (EN1993).
 It is a classification of structures according to:

 The consequences of a hypothetical collapse (life
or economic losses).
 The risks associated with the use of the structure (static
actions, fatigue, earthquake ...)
 Risks associated with the execution (grades of steel, welded
or bolted joints, ...)
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 The choice of the EXC is a decision of the designer of the

structure.
 Many requirements of EN 1090 are determined according to

the EXC, either in execution or in quality control. Table EN
1990-2 § A3 exhaustively listed the requirements for each
EXC.
 4 execution classes are established:

 EXC1 (the less strict) -> EXC4 (the most strict).
 The EXC suppose a rationalization of the design and the

execution. The cost of the structure increases with its EXC.
 The EXC can be applied to the whole structure or to single

parts or specific details . A structure may include several EXC.
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 How to choose the EXC:
1. Choose the Consequence Class (CC1, CC2 or CC3).

 The CC are indicated in Eurocode 0 (EN 1990
Annex B). The National Annexes may give additional
instructions.
EN 1990 § Annex B
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2. Choose the Service Category (SC1 or SC2).
EN 1090-2 §
B.2.2.2
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3. Choose the Production Category (PC1 or PC2).
EN 1090-2 §
B.2.2.3
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4. Choose the Execution Class (EXC1, EXC2, EXC3 o EXC4).
EN 1090-2 §
B.3
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 Practical examples of choosing the EXC:
1. Building for offices: Steel grade S275, welded in factory and

bolted on construction site. Not seismic zone.
 Consequence Class : CC2

 Service Category: SC1
 Production Category: PC1
 EXECUTION CLASS: EXC2
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2. Building for offices: Steel grade S355, welded on

construction site. Not seismic zone.
3. The same as above but in seismic zone, design in DCM or

DHC.
 It only changes the Service Category: SC2
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4. Structure for a stadium: Steel grade S355, welded in factory

and bolted on construction site. Not seismic zone.

 Service Category: SC1 (if one considers that the structure
can be subjected to vibration, SC2 )
 EXECUTION CLASS: EXC3 (if one considers that the
structure can be subjected to vibration, EXC4)
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5. Agricultural warehouse: Steel grade S275, welded in factory

and bolted on construction site (but columns joints welded on
construction site). Not seismic zone.
 Consequence Class: CC1

 Production Category: PC1 (but columns: PC2)
 EXECUTION CLASS: EXC1 (but columns: EX2)
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CE MARKING (EN 1090-1)
 The CE marking is a legal declaration of the fabricator of the

structure that their product fully complies with EN 1090-1 and
therefore meets the Construction Products Directive (CPD).
 Basic requirements:
 Initial Type Testing (ITT) or Initial Type Calculation (ITC).
 Factory Production Control (FPC), including the Welding
Quality Management System (WQMS).
 The role of the Responsible Welding Coordinator (RWC).
 Regular surveillance audits in factory and certification of the
manufacturer, by a Notified Body (NB).
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 Scope of EN 1090
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 Initial Type Testing (ITT) or Initial Type Calculation (ITC).
 Their objective is to obtain the performance of

each product manufactured.
 Since most of times the steels structures are fabricated as
“made-to-measure”, EN 1090-1 accepts the ITC as a
method of conformity assessment.
 The ITC developed for the design of the structure will have
to be based on the Eurocodes (EN 1990, EN 1991, EN
1993, EN 1994, EN 1998)
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CE MARKING
 ITT & ITC:

Sampling,
evaluation and
conformity criteria.
EN 1090-1 §
6.2 Table 1
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 Factory Production Control (FPC).
 EN 1090-1 defines the factory production controls required

to ensure that the structural steel components meet the
minimum technical requirements, as defined in EN 1090-2.
 The aim of the FPC is to ensure that the fabricator
can consistently produce their structural components
without changes to their characteristics.
 The FPC of the standard EN 1090-1 is similar to the Quality
Control of the standard EN ISO 9001 .
 The FPC should include the Welding Quality Management
System (WQMS).
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 Factory Production Control (FPC).
 FPC basis:
 To perform regular maintenance and calibration of
equipment and tools.
 To develop regular checkups to ensure conformity of
the manufactured products.
 To develop systematic management of non-conforming
products.
 Suitability of staff qualifications and work procedures.
 In general, if the production is done in agreement with EN
1090-2, most of the EN 1090-1 requirements are fulfilled.
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CE MARKING
 FPC:Frequency of
product testing as
part of factory
production control
EN 1090-1 §
6.3 Table 2
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 Welding Quality Management System (WQMS).
 WQMS basis:
 To consider the process of welding as a “special
process”, therefore controlling it constantly and with a
follow-up of the whole process.
 To develope and to control the internal procedures for
the execution of weldings.
 To control and to document that the staff that executes
the weldings holds a relevant and suitable
qualification.
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 The quality requirements must conform to

EN ISO 3834, depending on Execution Classes (EXC):
 EXC1: EN ISO 3834-4 Elementary

 EXC2: EN ISO 3834-3 Standard
 EXC3: EN ISO 3834-2 Comprehensive
 EXC4: EN ISO 3834-2 Comprehensive
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 The manufacturer must draw up their own welding

procedure specifications (WPS) (EN ISO 15609, EN ISO
14555, EN ISO 15620).
 WPS must be qualified by a welding procedure

qualification method (WQPR), according to the Execution
Class (EXC).
 Welders must be approved according to each WPS and

each welding position.
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 Development and use of a WPS
EN 1090-2 § Annex
L
33
 Development and use of a WPS
EN 1090-2 § Annex
L
Example:
WPQR
Example: Welder Qualification.
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 Responsible Welding Coordinator (RWC).
 The manufacturer must identify a RWC, which will be

responsible for the quality of the welds .
 RWC tasks:
 Review of contractual/technical welding requirements;
 Ensuring welding personnel are appropriately qualified;
 Suitability of welding and associated equipment;
 Writing welding procedure specifications (WPSs);
 Development/qualification of welding procedures;
 Production planning;
 Storage and handling parent materials and control of welding
consumables;
 Inspection and testing before, during and after welding.
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 Responsible Welding Coordinator (RWC).
 Technical knowledge of the RWC (EN ISO 14731):
EN 1090-2 § 7.4.3
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 The Notified Bodies (NB).
 The NB should validate, control and certify the proper

implementation of Factory Production Control (FPC),
including the Welding Quality Management System
(WQMS).
 Tasks:
 Initial inspection at the factory and review of
the PFC and WQMS, its procedures and successful
implementation.
 Issue the corresponding certificate, which will have a shelf life of 1
or 2 years.
 Carry out regular controls
and monitoring, with intervals
depending on the EXC.
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EN 1090-1 §
 Relevant clauses of EN 1090-2 to CE marking.
 Documentation: EN 1090-2 § 4 and Annex A

 Constituent products: EN 1090-2 § 5, 12.1 and 12.2
 Geometrical tolerances: EN 1090-2 § 11 and Annex D
 Welding and manufacturing procedures: EN 1090-2 § 6, 7
and 12.4
 Surface treatment and durability: EN 1090-2 § 10, 12.6
and Annex F
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 Routes
to CE
marking
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FABRICATION AND EXECUTION (EN 1090-2)
 Execution Specification (EN 1090-2 § 4.1)
 EN 1090 requires a high involvement of the designer in

manufacturing, execution and quality control issues.
 Execution specification:
 Execution Classes (EXC). EN 1090-2 § 4.1.2
 Steel preparation grades. EN 1090-2 § 4.1.3
 Geometrical tolerances. EN 1090-2 § 4.1.4
 Safety of the erection works. EN 1090-2 § 4.2.3 and 9.2
 Additional information. EN 1090-2 § A.1
 Options. EN 1090-2 § A.2
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 Execution Specification (EN 1090-2 § 4.1)
 A good starting point to prepare an Execution

Specification are the guides "Model Construction
Specification " of the European project “Sechalo”.
 Multi-story buildings. Part 7: “Model construction Specification”

 Single story buildings. Part 10: “Model construction Specification”
http://www.arcelormittal.com/sections/index.php?id=167
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 Constructor's documentation (EN 1090-2 § 4.2)
 Quality documentation (shall be documented for EXC2,

EXC3, EXC4) : EN 1090-2 § 4.2.1
 Organisation chart, staff, requirements ...
 The procedures, methods and work instructions.
 An inspection plan specific to the works, including hold points..
 A procedure for handling of non-conformities and changes.
 Quality plan:
 The allocation of tasks and authority. EN 1090-2 § 4.2.2
 Quality documentation.
 Records of inspections and checks.
 EN 1090-2 § Annex C -> Check-list for the content of a
quality plan.
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 Constituent products (EN 1090-2 § 5)
 EN 1090-2 indicates the Product Standards for almost all

of the most common construction products related to
steel structures fabrication.
 Traceability: For EXC3 and EXC4, constituent products
shall be traceable at all stages from receipt to hand over
after incorporation in the works..
 For EXC2, EXC3 and EXC4, if differing grades or qualities of

constituent products are in circulation together, each item
shall be designated with a mark that identifies its grade.
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 Preparation and assembly (cutting, shaping, holing and

assembly) (EN 1090-2 § 6)
 Cutting:
 Methods: sawing, shearing, disc cutting, water jet
techniques and thermal cutting.
 In general, the capability of cutting processes shall be
periodically checked -> (EN 1090-2 § Table 9)
 Hardness of free edge surfaces (thermal cutting, shearing,
punching):
(EN 1090-2 § Table 10)

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Thermal cutting
Sawing
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 Shaping:
 Hot forming: Shall conform to the requirements of the
relevant product standard.
 Flame straightening
 Maximum steel temperature and procedure of cooling must be
controlled.
 For EXC3 and EXC4 a suitable procedure shall be developed
(maximum temperatures, methods, testing, identification of
workers, etc..)
 Cold forming:
 Shall conform to the requirements of the relevant product
standard.
 Reduction of ductility must be controlled.
 EN 1090-2 specifies the appropriate geometric parameters
(bending radii, overall ratio, etc ...)
47
Cold forming - pressed
Cold forming - rolled
48
 Holing:
 Dimensions of holes:
(EN 1090-2 § Table 11)

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 Holing:
 Execution of holing:
 Methods: drilling, punching, laser,
plasma or other thermal cutting.
 In general, the capability of holing
processes shall be periodically checked.
 Punching: The nominal thickness of the
component shall be smaller than the
nominal diameter of the hole.
 For EXC3 and EXC4 and t ≥ 3 mm,
punching without reaming is not
permitted. The holes shall be punched
at least 2 mm undersize in diameter.
Permitted distortions
 For sheets and plates where t ≤ 3 mm,
(EN 1090-2 § 6.6.3)
holes may be formed by full size
punching.
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Drilling
Finished holes
51
 Cut outs
 Over-cutting of re-entrant
corners shall not be
permitted.
 Minimum radius:
EXC2 and EXC3: r > 5 mm.
EXC4: r > 10 mm.
 Assembly:
 Assembly of components shall be carried out so as to fulfil the
specified tolerances.
 Precautions shall be taken so as to prevent galvanic corrosion.
 The fit between components shall be checked using
dimensional templates, three-dimensional measurements or
by trial assembly. 52
Good cut out
Assembly
53
 Welding (EN 1090-2 § 7)
 A welding plan shall be provided as part of the production

planning, that shall include:
54
 Welding plan (cont.):
55
Preparation before
welding
56
Execution of welding
57
Lamellar
tearing
58
 Preparation and execution of welding

 Recommended standards: EN ISO 9692-1 and EN ISO 9692-
2
 Joint preparation shall be free from visible cracks, dry and

without primers.
 Prefabrication primers (shop primers) may be left on the

fusion faces only for EXC1 and ECX2..
 Hollow sections: EN 1090-2 § Annex E - > Guide for the

execution of Welded joints in hollow sections.
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 Preparation and execution of welding
 Temporary attachments:
 Must be executed according to the WPS.
 EXC3 and EXC4: The use of temporary attachments should be
specified.
 Tack welds:
 EXC2, EXC3 and EXC4: Tack welds shall be made using a qualified
welding procedure.
 Minimum length: Shall be the lesser of four times the thickness of
the thicker part or 50 mm.
 If tack welding is going to be incorporated in the final weld, it must
be free from defects and executed by qualified welders.
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 Fillet welds:
 Main criteria: Correct throat thickness, correct length and
absence of surface defects.
 Butt welds:
 Main criteria: To ensure the full penetration and suitability
of the root of the weld.
 Single sided welds: Can be executed with or without a
backing material. If backing material is used, it must be
specified in the WPS
 Other types of welds described in EN 1090-2:

 Stud welding.
 Slot and plug welds.
 Spot welds.
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 Acceptance criteria:
 Defined in EN ISO 5817, depending on the Execution Class.

 EXC1: quality level D
 EXC2: quality level C
 EXC3: quality level B
 EXC4: quality level B and the requirements in EN 1090-2 § Table 17
 The acceptability of imperfections can be evaluated using

also the following standards: EN 1993-1-1, EN 1993-1-9 and
EN 1993-2.
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 Example of acceptance criteria: standard EN ISO 5817 § 5.
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 Mechanical fastening (EN 1090-2 § 8)
 Bolts and nuts shall not be welded.
 The nominal fastener diameter used for structural bolting
shall be at least M12.
 Minimum lengths:
 Non-preloaded bolts: At least one full thread shall remain clear.
 Preloaded bolts: At least four full threads shall remain clear.
 Nuts shall run freely on their partnering bolt. Otherwise,
nut and bolt shall be discarded.
 Washers:
 Non-preloaded bolts: In general, washers are not required.
 Preloaded bolts: Grade 8.8 -> One washer under the
element to be rotated.
Grade 10.9 -> Two washers (one under
64 each element).
 FABRICACIÓN Y
EJECUCIÓN (EN 1090-
2)
Bolted joints
65
 Difference of thickness
D < 2 mm in general.
D < 1 mm for preloaded
joints.
 If steel packing plates are used, their thickness shall not be

less than 2 mm.
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 Preloaded bolts – HR system
 English and French

version of the preloaded
bolts.
 The related European
standard is EN 14399-3.
 The threaded area is long
and wide nuts are used.
 HR bolts are less sensitive to the excesses of preloaded,

compared with HV bolts. In addition, if applied load exceeds
the required prestressing load, the bolt breaks, so the fault is
very clear.
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 Preloaded bolts – HV system
 German version of the

preloaded bolts.
 The related European
standard is EN 14399-4.
 The threaded area is
short and narrow nuts are
used.  In Spain, HV system is
used more than HR
system.
 HV bolts are more sensitive to the excesses of preloaded,
compared with HR bolts. In addition, if applied load exceeds
the required prestressing load, the threaded are plastifies, so
the fault is hard to detect.
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 Tightening of bolts:
 The tightening process shall be carried out starting from
the most rigid part of the connection and moving
progressively towards the least rigid part.
 Preparation of contact surfaces in slip resistant connections.
(EN 1090-2 § Table 18)

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 Tightening of preloaded bolts.

 Nominal minimum preloading force: Fp,C = 0.7 fub As
fub: nominal ultimate strength of the bolt material
As: stress area of the bolt
(EN 1090-2 § Table 19)
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 Tightening of preloaded bolts.

 Tightening methods:
EN 1090-2 § 8.5.3
EN 1090-2 § 8.5.4
EN 1090-2 § 8.5.5
EN 1090-2 § 8.5.6
(EN 1090-2 § Table 20)
The k-class indicates the "as-delivered calibration condition“.
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Torque wrench
Hard to reach preloaded

joint.
72
 DTI washers (direct

tension indicator):
 Simplifies the preloaded

joints execution and QC
inspections.
 Their cost is high.
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 Other types of mechanical fastening described in EN 1090-2:
 Hot riveting. EN 1090-2 § 8.7
 Fastening of thin gauge components:

 Self-tapping and self-drilling screws. EN 1090-2 § 8.8.2
 Blind rivets. EN 1090-2 § 8.8.3
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 Erection at site (EN 1090-2 § 9)
 Erection shall not commence until the site for the

construction works complies with the technical
requirements with respect to the safety of the works,
indicated in EN 1090-2 § 9.2.
 Erection method (EN 1090-2 § 9.3.1 and 9.3.2).

 Designer: A basic method of erection must be drafted, according to
the Project, to ensure structural stability during the execution.
 Constructor + Designer: A Construction Procedure should be
drafted, describing the method of erection of the constructor,
which should be checked in accordance with the design rules
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 Supports, anchors and bearings:

 The condition and location of the supports shall be checked using
appropriate visual and measurement means before the
commencement of erection.
 The location and levels of the supports, anchors or bearings shall
comply with the acceptance criteria described in EN 1090 § 11.2.
 Any non-conformity shall be documented.
 Grouting and sealing:

 Main criteria: The free space under
the base plate must be completely
filled (right consistency, proper
disposal, vent holes, ...)
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 Erection drawings:
 Erection drawings shall be provided and form a part of the
erection method statement.
 Drawings shall show details and arrangements of any
temporary works necessary to ensure the stability or the
safety of personnel.
 Drawings shall state the weight of all components or
assemblies over 5 tonnes and the centre of gravity of all
large irregular pieces.
 Marking:
 Components that are individually assembled or erected at
the site shall be allocated an erection mark (with their
orientation if this is not clear).
77
78
 Steelwork damaged during off-loading, transportation, storage

or erection shall be restored to conformity:
 EXC2, EXC3, EXC4: The procedure for restoration shall be
defined before undertaking the repair and documented.
 For buildings, at least one third of the permanent bolts in each
connection should be installed before that connection can be
considered to contribute to stability of the part completed
structure.
 Fit-up and alignment
 Each part of the structure shall be aligned as soon as
practicable after it has been erected.
 Permanent connections shall not be made between
components until sufficient of the structure has been
aligned, levelled and plumbed.
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 Surface treatment (EN 1090-2 § 10 and Annex F)
 EN 1090-2 does not indicate the detailed technical

requirements, which should be consulted in:
 Paints and varnishes: EN ISO 12944 and EN 1090 – Annex F
 Metal coating by thermal spraying : EN 14616, EN 15311 and EN
1090 – Annex F
 Metal coating by galvanizing: EN ISO 1461, EN ISO 14713 and EN
1090 – Annex F
 Performance Specification (designer):

 Expected life of the corrosion protection (maintenance
programme): EN ISO 12944-1
 Corrosivity category: EN ISO 12944-2
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 Expected life of the corrosion protection (EN ISO 12944-1 § 4.4)
 Indicates the time between repairs of the paint system.
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 Corrosivity categories (EN ISO 12944-2 § 5 )
82
 Tables for paint specifications (EN ISO 12944-5 )
 EN ISO 12944-5 indicates different possible combinations of

paints to ensure the durability of the protection under each
category of corrosivity.
 These tables are very useful when designing a paint system

for a steel structure corrosivity protection .
83
 Exemple for corrosivity category C3 (EN ISO 12944-5 )
84
 Exemple for corrosivity category C3 (EN ISO 12944-5 )
85
 Preparation of steel substrates:

 All surfaces to which paints are to be applied shall be
prepared to meet the criteria of EN ISO 8501. The
preparation grade shall be specified in the project
(example: SA 2 ½)
86
(EN 1090-2 § Table 22)
 Geometrical tolerances (EN 1090-2 § 11 and Annex D)
 Essential tolerances: Needed for the mechanical resistance

and stability of the completed structure. (EN 1090-2 §
Annex D.1).
 Functional tolerances: to fulfil other criteria such as fit-up

and appearance (EN 1090-2 § Annex D.2).
 It is recommended that the designer specifies the class of

the functional tolerances (Class 1 or Class 2).
87
 Inspection, testing and correction(EN 1090-2 § 12)
 All inspection and testing shall be undertaken to a

predetermined plan with documented procedures.
 All inspection, testing and associated corrections shall be
documented.
 Constituent products:
 All documents supplied with constituent products shall be checked.
 Traceability must be checked.
 Geometrical dimensions of manufactured components:
 The geometry of the components should be always checked.
 The location and frequency of measurements must be specified in
the inspection plan.
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 Welding inspection
 Visual inspection: All welds shall be visually inspected

throughout their entire length.
 Non destructive testing (NDT):

 Penetrant testing (PT): EN 571-1.
 Magnetic particle inspection (MT): EN 1290.
 Ultrasonic testing (UT): EN 1714 and EN 1713.
 Radiographic testing (RT): EN 1435.
 All tests must be performed by Inspectors NDT Level 2 (EN

473).
89
 Fillet welds:
 Visual inspection (VI), Dimensional Control (DC), Penetrating Liquids
(LT) y Magnetic particle inspection (MT).
DC MT
Lt
90
 Butt welds:
 Visual inspection (VI), Dimensional Control (DC) of the pre-asembly,
Ultrasonic testing (UT), Radiographic testing (RT).
DC
UT
91
 Scope of
inspection
(NTD)
(EN 1090-2 § Table 24)

92
 NDT for the start of the production:
 For the first 5 joints made for a new WPS, a more stringent
inspection is needed:
 The quality level B is required.
 The % to be tested shall be double of the values in Table 24 (min.
5%, max. 100 %).
 The minimum length to be inspected is 900 mm.
 Correction of welds:
 EXC2, EXC3 and EXC4: Repairs by welding shall be carried
out in accordance with qualified welding procedures and
checked.
93
 Minimum hold times for NTDs:
(EN 1090-2 § Table 23)
94
 Inspection of mechanical fastening
 All connections with mechanical fasteners shall be visually

checked before and after the assembly.
 If the connections incorporate friction surfaces the surfaces
shall be visually checked immediately before assembly.
 Inspection of preloaded bolted connections

 The type of inspection depends on the tightening method:
 Torque method: EN 1090-2 § 12.5.2.4
 Combined method: EN 1090-2 § 12.5.2.5
 HRC method: EN 1090-2 § 12.5.2.6
 Direct tension indicator method: EN 1090-2 § 12.5.2.7
95
 Number of bolt assemblies inspected overall in a structure:
 EXC2: 5 % for the second step of the torque or the

combined method and for the DTI method.
 EXC3, EXC4: 5 % for the first step and 10% for the second
step of the combined method.
10 % for the second step of the torque
method and for the DTI method.
 The inspection shall be carried out using a sequential sampling

plan according to EN 1090-2 § Annex M
96
Torque method control with
torque wrench
Preloading control with DTI
97
 Inspection of the corrosion protection EN 1090-2 § Annex F
 Proper preparation of steel surfaces which are to receive

corrosion protection treatment must be verified.
 Thickness measurement:
 Layer of the paint coating: EN ISO 19840 and EN ISO 2808
 Metal coating: EN ISO 2063
 Galvanizing: EN ISO 1461
 Paint systems: Adherence tests shall be performed if the

project indicates it.
98
Inspection of the preparation of Thickness measurement

the steel surface
99
 Inspection of erection
 The condition of the erected structure shall be inspected

for any indication that components have been distorted or
overstressed, and to ensure that any temporary
attachments have been removed.
 Geometrical position of connection nodes:

 A survey of the completed structure shall be made.
 EXC3 and EXC4: The survey shall be documented.
100
CONCLUSION
CONCLUSION
 The new European standard for fabrication and execution, EN

1090, will be mandatory from 2014.
 EN 1090-1: Regulates the CE marking in steel structures.
 EN 1090-2: Comprehensively explains the minimum technical
requirements for the fabrication and execution of steel
structures.
 The choice of the Execution Class determines the cost of the
structure (affects fabrication methods, level of inspections,
etc.).
 EN 1090 requires greater designer's involvement in the
requirements for fabrication, execution and quality control.
102
REFERENCES AND ACKNOWLEDGEMENTS
REFERENCES
 EN 1090: Execution of steel and aluminium structures
 Part 1: Requirements for conformity assessment of
structural components.
 Part 2: Technical requirements for the execution of steel
structures.
 EN 1990 – Eurocode 0: Basis of structural design.
 EN ISO 5817: Fusion-welded joints in steel, nickel, titanium
and their alloys. Quality levels for imperfections.
 EN ISO 12944: Corrosion protection of steel structures by
protective paint systems.
 ECCS TC 9. Guide to the CE Marking of Structural Steelwork.
1st Edition, 2011. ECCS – European Convention for
Constructional Steelwork.
104
PICTURES ACKNOWLEDGEMENTS
 Rationing (Engineering firm): www.ratio-n-ing.com
 Applus+ (Quality Control firm): www.applus.com
 Grupo Salmeron (Steelwork fabricator):

www.gruposalmeron.com
 FATOR (Bolt fabricator): www.tindsa.com
 Applied Bolting (Bolt fabricator): www.appliedbolting.com
105
SKILLS training modules have been developed by a consortium of organisations whose logos appear at the bottom
of this slide. The material is under a creative commons license
The project was funded with support from the European Commission. This module reflects only the views of
the authors, and the Commission cannot be held responsible for any use which may be made of the information
contained therein.

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FABRICATION AND EXECUTION – EN1090

NOTE: This learning module is designed to be used

 EN1090, a new standard for fabrication and execution of

 Execution Classes (EXC).

 CE Marking for steel structures.

 Designer's involvement in the requirements for fabrication

 Technical requirements for fabrication and execution.

 Introduction. Regulatory framework.

 Execution Classes (EXC)

 CE Marking (EN 1090-1)

 Fabrication and execution (EN 1090-2)

 The Construction Products Directive (CPD)

 The CPD essential 1. Mechanical resistance and stability.

 Compliance with the essential requirements:

 There are other methods to meet the essential requirements

Regulatory framework  EN 1090-1: Requirements for conformity

 Full list -> EN 1090-1 § 2 + EN 1090-2 § 2

 The “Execution Classes” is one of the most important new

 Come from the Eurocode 0 (EN 1990) and will be trasnferred

 It is a classification of structures according to:

 The choice of the EXC is a decision of the designer of the

 Many requirements of EN 1090 are determined according to

 4 execution classes are established:

 The EXC suppose a rationalization of the design and the

 The EXC can be applied to the whole structure or to single

 How to choose the EXC:

1. Choose the Consequence Class (CC1, CC2 or CC3).

2. Choose the Service Category (SC1 or SC2).

3. Choose the Production Category (PC1 or PC2).

4. Choose the Execution Class (EXC1, EXC2, EXC3 o EXC4).

 Practical examples of choosing the EXC:

1. Building for offices: Steel grade S275, welded in factory and

 Consequence Class : CC2

 Practical examples of choosing the EXC:

2. Building for offices: Steel grade S355, welded on

3. The same as above but in seismic zone, design in DCM or

 Practical examples of choosing the EXC:

4. Structure for a stadium: Steel grade S355, welded in factory

 Consequence Class : CC3

 Practical examples of choosing the EXC:

5. Agricultural warehouse: Steel grade S275, welded in factory

 Consequence Class: CC1

 EXECUTION CLASS: EXC1 (but columns: EX2)

 The CE marking is a legal declaration of the fabricator of the

 Initial Type Testing (ITT) or Initial Type Calculation (ITC).

 Their objective is to obtain the performance of

 ITT & ITC:

 Factory Production Control (FPC).

 EN 1090-1 defines the factory production controls required

 Factory Production Control (FPC).

 Welding Quality Management System (WQMS).

 Welding Quality Management System (WQMS).

 The quality requirements must conform to

 EXC1: EN ISO 3834-4 Elementary

 Welding Quality Management System (WQMS).

 The manufacturer must draw up their own welding

 WPS must be qualified by a welding procedure